Autoteam Edition No. 1
Autoteam Edition No. 1
So many changes
The all new Ford Transit
Another first for Ford The new DuraTorq engine Keep it clean Your personal safety
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Comment
Autoteam 2000
In past issues of Autoteam many articles have dealt with change: change in
the business environment, change in technology, change in customer expec-
tations. Now Autoteam itself has changed.
Probably, you will already have noticed a few things that are different
about this issue of Autoteam. Many differences are in the areas of design
and layout – items that have changed a number of times in the history of
Autoteam.
But two items have now changed for the first time since Autoteam was first
published:
With regard to the Autoteam logo itself, this was meanwhile 11 years
old and, even when it first appeared, was based on the typography of
Autoteam’s predecessor, Autotek. Although we’ve all become used to the
logo, its design had meanwhile become somewhat old-fashioned. And
‘old-fashioned’ is an attribute we certainly don’t want for Autoteam. The
Cover picture: new logo has – we believe – a more attractive and contemporary look,
The new Transit, the new autoteam-Logo and the that better represents what we want Autoteam to stand for: a modern
new cover-design, all in one! and progressive publication that keeps its readers well informed of latest
developments.
And because more than just design and logo will change, we found it
appropriate to document the start of a fresh and new Autoteam generation
with a new issue numbering sequence. That’s why this issue is numbered
1/2000.
Published by:
Ford of Europe Incorporated
Ford Customer Service Division
Produced by Palmer Hargreaves Team
2 autoteam 1•2000
Inhalt
So many changes... 4
The New Transit: Autoteam
provides you with an overview
of the new vehicle and some of
its technological innovations
Crystal clear 16
A success story of mobile glass-repair
Keep it clean. 24
Is a workshop a dangerous place to work?
It depends largely on yourself
TSB résumé 29
Competition 29
Ford Facts 32
Lost your bearings? 18 Ford – a century ahead of its time
autoteam 1•2000 3
So many changes...
...they’re beginning to show.
The new Transit was launched Transit was launched back in 1965 and has wheel drive later in 2000) and 75PS, 90PS
across Europe in the early part of been the leader in its class for over 33 and 120PS from a 2.4-litre version power
this year. Here, we provide you years. In that period, more than 4 million the Transit. A specially developed version of
with an overview of the new vehi- vehicles have been sold world-wide. Now, the 2.3-litre DOHC petrol engine will be
cle with the aim of identifying for the first time in over ten years, an all- available later in the year as an option on
some of its technological innova- new Transit has been launched. the rear-wheel drive model.
tions.
The new Transit comes in short, medium Service intervals are increased to 25 000
and long wheelbase form, all from the same km (15 000 miles).
platform. Rear-wheel drive is available
from the outset on long and medium Rear-wheel drive versions feature an up-
wheelbase versions, while front-wheel drive graded version of MT75, with a new dual-
is scheduled for the first time on Transit mass flywheel to reduce noise and vibration.
later this year. A specially developed ver- The New Transit transmission casing is
sion of the 2.3-litre DOHC petrol engine based on the Scorpio transmission with
will also be available later in the year as an additional stiffening ribs for added strength.
option on the rear-wheel drive model. The gearshift mechanism is located behind
the transmission secured by two bolts to a
Powertrain and transmissions crossmember and is not adjustable. Despite
A new family of 16V DuraTorq diesel the similarities, the new Transit MT75
engines producing 75PS, 90PS and 105PS transmission is not interchangeable with
from a 2.0-litre engine (available on front- earlier Transit models or Scorpio.
4 autoteam 1•2000
Automatic Shift Manual (ASM) is scheduled
for early 2001 for front-wheel drive versions,
and will feature a fully hydraulic, self-
adjusting clutch to ensure smoother shifting.
Variable rate front coil springs, combined
with new, larger tyres provide enhanced
traction, stability and durability. There has
also been a lot of work done using comput-
er-aided engineering to improve braking,
steering, ride and handling.
Body
The sides of the body load area are more
upright, providing 11 per cent more load
space. Additionally, two sizes of side door
are available. The driver also gains an im-
proved view thanks to backward sloping The fixed drop-waist quarter windows are mounted in rubber.
B-pillars and new drop-waist side windows.
Panel van body panels are all manufactured Both front fenders and new plastic front For the first time, fixed side and rear win-
from sheet steel. And all body skin panels crossmember are ‘bolt on’, making accident dows are bonded directly to the frames,
are coated with zinc to help prevent attack repairs simple and economical. with only the front door quarter lights
from corrosion. being mounted in rubber.
The first wave of city slickers. Big on both style and practicality, Transit is being introduced in two stages: the first being the rear-
wheel-drive, 2.4 litre DuraTorq variants.
autoteam 1•2000 5
Chassis systems The front brake calipers are mounted
Transit now has a new front axle with towards the front of the vehicle and
McPherson struts, transverse arms, sub- each incorporates two pistons of 48
frame and stabiliser bar, resulting in savings mm diameter.
in both weight and space. This system is
also able to accommodate the front wheel
drive configuration without modification.
This all makes the Transits’ front suspension
system similar in principle to that of a car.
The new shape headlamps utilise ‘free The inner brake disc pads have an accoustic
form’ reflectors and lens made of non-pro- brake pad wear indicator fitted. The indica-
filed plastic. Three nuts and a bolt retain tor consists of a wire, which is secured to
each unit. the brake pad. When the brake pads reach
a pre-determined level, the wire contacts
Security hasn’t been forgotten either. The the brake disc and produces a clearly audi-
new Transit has the most advanced security ble noise.
system of any commercial vehicle: a stand-
ard Safeguard (PATS) engine immobiliser, The anti-lock braking system fitted on the
lock-in-latch and Ford Focus-style locking new Transit is the Bosch 5.3, and is com-
bonnet. bined as standard with electronic brake
force distribution. A further option is a
Inside, the fully adjustable drivers’ seat brake traction control system (BTCS) which
includes lumbar support, tilt and recline, can also be switched off if necessary.
height adjustment and extra seat travel.
Heating, ventilation and audio controls are Better by design
placed higher on the instrument panel to Since its introduction over 30 years ago, the
allow the driver to use them without hav- Ford Transit has consistently been among
ing to lean forward or to take his eyes off the best selling commercial vehicles in
the road. The driver’s airbag, which comes Europe. This latest model is a logical devel-
as standard is larger. A passenger airbag is opment based on the many years success of
available as an option. The centre seat the Transit range.
passenger gets a three-point fixing seat
belt, while the other two seats gain height
adjustable belts. These features help to
make the new Transit safer than ever.
6 autoteam 1•2000
Twenty things you should know about the new Transit
1 New Transit has extended service intervals. Scheduled servicing 11 If injector pipe connections are loosened/disconnected, the
is every 25 000 km (15,000 miles). A service indicator light is injector pipes MUST BE RENEWED.
located in the instrument cluster and controlled by the PCM.
It will illuminate when vehicle operating demands have led to
a deterioration of the engine oil. 12 To avoid air ingress into the fuel system should the vehicle
run out fuel, a sensor cuts the engine out at a predetermined
minimum level of fuel left in the fuel tank. On being refilled
2 Mechanical filter warning indicators (minders) are attached the vehicle will start without the need for air to be bled out
to the air and fuel filters. These filters should be changed of the fuel injection system.
when the indicator is in the clear, and must be changed
when in the red sector of the minder.
13 Dependent on variant, the rear wheel drive Transit has differ-
ent wheel hubs. Single rear wheeled vehicles have front and
3 The fuel filter has a water trap. A water trap warning light rear wheel hubs with five wheel studs. Twin rear wheeled
is fitted in the instrument cluster to warn that the water in vehicles have front and rear hubs with six wheel studs.
the trap should be drained as soon as possible.
14 The brake disc is bolted to the front wheel hub, so that the hub
4 The new Transit can only be interrogated by the WDS must be removed in order to remove the brake disc.
diagnostic tool. FDS2000 does not support this model.
15 All variants are fitted with mechanical audible brake pad wear
5 The powertrain control module data link connector is
indicators. ABS with EBD (Electronic Brake force Distribution)
located under the steering column.
is optional. Low speed traction assist is also optional, the system
only operates at speeds of less than 40 km/h (25 miles/h).
19 The rear doors have a new check strap design with a push
9 The ‘DuraTorq’ diesel engine uses a timing chain rather button release.
than a synchronous belt.
autoteam 1•2000 7
The boiling point
From the 1st April 2000 Ford has reduced When water reaches the boiling point, it is extremely useful – from boil-
the service interval for brake fluids from 3 ing eggs to washing dirty linen. When brake fluid reaches the boiling
to 2 years. These new service intervals also point it becomes useless – and, even worse, extremely dangerous.
apply retrospectively for older vehicles –
although the service literature provided up
to April 2000 shows three-year intervals. The functions Brake fluids absorb moisture – they are
The nerve centre of a vehicle’s braking hygroscopic. This is intentional because
Customers of older vehicles may well ask system is the hydraulic system. Its main water penetration into sealed brake systems
for an explanation why their brake fluid component is the brake fluid and this has is quite normal. Moisture seeps in through
should be changed earlier than stated in the several functions: microscopic pores in the rubber seals and
service literature. So this article gives you hoses, or when the master cylinder reservoir
the necessary background to convince your ■ First and foremost is to transmit the is opened to check the fluid level.
customers that Ford and your dealership mechanical pressure applied to the brake
have only their safety in mind. pedal to the brakes so that the car is In fact, brake fluid is so hygroscopic, that
decelerated and braked safely. leaving the lid off a fresh can of brake fluid
can ruin it overnight, because it will absorb
■ In addition, brake fluids are designed to so much water from the air that it becomes
absorb heat – particularly important to too contaminated to use.
deflect the high heat away from the
wheel cylinder assemblies and the brake Under normal conditions, the brake fluid
Braking Power callipers. of a typical vehicle will contain about 2%
water after one year. After several years of
The power required to effectively ■ And brake fluids are also formulated to service, it’s not uncommon to find brake
brake a car is much higher than that absorb moisture, prevent corrosion and fluid containing 7% to 8% of water.
needed to accelerate and drive the car. to act as a lubricant.
A well known sports car is capable of What water does to the system
accelerating from standstill to 100 What happens over time? Moisture contamination causes the rubber
km/h in 6 seconds – and it needs 408 Fresh brake fluids have a very high boiling components in the system to swell and can
hp to achieve this. The same car can point, ranging from 205° C to 260° C. This eventually cause a leak. Moisture can also
brake from 100 km/h to standstill in is necessary to prevent the fluid from boil- lead to rust and corrosion in the braking
28 metres. The braking power needed ing when it absorbs part of the heat gener- system (master cylinder, steel brake lines,
for this is equivalent to 1,200 hp. ated by braking. wheel cylinders, etc.). If the vehicle has an
8 autoteam 1•2000
anti-locking system, replacing corroded ABS
260° C
modulators can be expensive. Within 2 – 3 years
°C
the boiling point
In addition, water changes the viscosity of of a high quality
the brake fluid by thickening it. The conta- brake fluid can
minated fluid becomes sluggish and flows drop from 260°C
more slowly in cold temperatures, resulting to 160°C.
in reduced braking performance in winter
conditions.
autoteam 1•2000 9
New Transit
has an all-
new 2.4 litre
DuraTorq
diesel engine.
10 autoteam 1•2000
Engine component location
(Left side and rear).
clutch housing and the intake manifold 1 Stiffening frame.
1 EGR valve. side of the engine. Bolted beneath the stiff- 2 Oil pump.
2 EGR cooler ening frame is the pressed steel sump.
(Not fitted to 75 PS variants).
3 Dual mass flywheel and The gear-type oil pump is bolted to the
clutch assembly. underside of the stiffening frame and is
4 Oil filter. powered directly from the crankshaft by a
5 Oil cooler. separate chain drive. A hydraulic tension-
6 Fuel injection pump. er/guide keeps the chain properly ten-
sioned. When the oil pump is installed, the
drive sprocket on the oil pump must be
1 aligned precisely with the sprocket on the 1
crankshaft. The correct installation proce- 2
2 dures for the oil pump, stiffening frame
and sump are fully explained in the current casing is based on the Scorpio transmission
service literature. with additional stiffening ribs for added
strength. The gearshift mechanism is locat-
Injection pump ed behind the transmission secured by two
At the heart of the fuel system lies the fuel bolts to a crossmember and is not
3 injection pump. Technicians will encounter adjustable. Despite the similarities, the new
two versions of the Bosch distributor-type Transit MT75 transmission is not inter-
4 injection pump dependent on engine. The 75 changeable with earlier transit models or
6 5 and 90 PS engines are fitted with theVP 30, Scorpio.
while the 120 PS engine utilises the VP 44
pump. Making its debut teamed with the new
If the cylinder head gasket is simply being Transit, the 2.4 DuraTorq is certainly start-
renewed, a gasket with the same markings The VP 30 is currently in use on the Endura- ing its life in fine company.
can be used. However, if pistons or con- DI in the Ford Focus. While the VP 44 is a
necting rods are being renewed, the piston radial-piston, high pressure pump, with its
bump height must be measured and the principles based on the Lucas DPC(N) dis-
appropriate thickness gasket installed. tributor fuel injection pump used in the
Escort and Mondeo.
There are two different size bolts retaining
the cylinder head: ten M10 x 160 mm bolts At the “business end” of the fuel system are
and eight M8 x 120 mm bolts. As the the injectors. Each of the injectors is screwed
cylinder head bolts are “torque to yield“, vertically into the cylinder head, centrally
when refitting the head, always use new between the four valves. A new special tool
bolts and tighten them in the specified (No. 21-273) must be used when fitting the
sequence. injectors. The steel injector sealing washers
must not be changed, turned or mixed up
Stiffening frame during service operations.
To reduce noise levels, a die-cast aluminium
stiffening frame is fitted to the lower part Powertrain
of the cylinder block. The frame design also There are two transmissions available. At-a-glance Specifications
includes an integral baffle to reduce the risk Rear-wheel drive versions feature an
of oil foaming. When installing the stiffen- upgraded version of MT75, with a new ■ 4-cylinder turbocharged diesel engine
ing frame, ensure that it is aligned with the dual-mass flywheel to reduce noise and ■ Two overhead camshafts and
vibration. The New Transit transmission 16 valves
■ Chain-driven camshafts
■ Valves operated by rocker arms with
hydraulic tappets
■ Cylinder block stiffening frame
1 ■ Chain-driven oil pump mounted
2 under the stiffening frame
■ Oil cooler with integral oil filter
■ Charge air cooled by intercooler sys-
tem (not on 75 PS variant)
■ Bosch (VP 30 or VP 44) fully elec-
Fuel injection pumps. tronic fuel injection pump
Cylinder head 1 VP 30 (75 and 90 PS engines). ■ Electric fuel lift pump (120 PS only)
assembly. 2 VP 44 (120 PS engines).
autoteam 1•2000 11
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Promo
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Promo
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Marketing
for everybody
■ If you believe this is an article marketing, you have an important concept of marketing, which will give you
for Marketing Managers, you are part to play in your dealership’s a better understanding of the marketing
mistaken. marketing. activities Ford and your dealership are in-
volved in. And you will be shown practical
■ If you believe marketing is just Over time Autoteam has featured many examples that demonstrate your role in
about selling and advertising, you articles about specific marketing topics, marketing and how you can provide a
are mistaken. Ford frequently announces new marketing valuable contribution to the marketing
programs, and your dealership may well success of your dealership.
■ If you believe that in your job have its own marketing activities.
you have nothing to do with What is marketing?
marketing, you are mistaken. Because you are affected by marketing and There are many definitions of marketing.
have a role to play, it’s important that you One of the reasons for that is that the
If you work as a Technician or understand what marketing is. But don’t definition changes over time, as you’ll see
Service Advisor – or, in fact, if you worry – this will not be a textbook about a bit later. The most adequate definition is
are anyone working in a dealer- marketing theory. This article, and further the following:
ship – you are not only affected by articles to come, will acquaint you with the
12 autoteam 1•2000
Marketing is everything that is An example are renowned manufacturers customer. If you look back at the definition
done in a company to influence of mechanical watches who continued of marketing earlier in this article, you will
how well that company, its to produce and promote their expensive see that this is exactly what it describes.
products and its services satisfy products at a time when the market demand
the needs of the company’s had shifted to moderately priced quartz The elements of marketing
customers. watches. But other industries were equally The above description of marketing is at a
affected. pretty high level and still somewhat theo-
So if you in any way are engaged in an retical. To add more meaning, let’s have a
activity that influences what existing or What these companies failed to realise, look at the elements of marketing.
potential customers may think about the was that customer needs and desires change
company you work in, the products it sells over time. And as other companies recog- As already said, marketing needs to take
or the services it provides, you have a role nise these needs and satisfy them, those many things into account and because the
to play in marketing. that don’t lose their business. individual ingredients of integrated mar-
keting need to be “mixed” for best results,
This was not always the case. Forty years Because of this, successful companies take the term “marketing-mix” is frequently used
or so ago many standard textbooks on a different approach. They determine what to describe how the individual elements
business management did not even include customers require and structure all their fit together. Basically, the marketing-mix
the word “marketing”. A major reason was activities to satisfy these customer needs. consists of five elements:
that many companies totally focused on the The consideration of all company activities
product they produced and their sales and in ensuring that customer requirements are Product, Price, Place, People,
promotion activities concentrated on selling met, can be called integrated marketing Promotion
that product. because it integrates so many activities in Let’s have a look at each of these five ele-
a company. ments to determine exactly what is meant.
Focus: Activity:
The product Promote & sell Focus: Activity:
Customer Integrated
requirements marketing
The activities in such companies totally
concentrated on the needs of the company
as a producer or seller. This appears logical In contrast to the “traditional” way of
at first sight, but it was this view of business doing business (see above) the activities
that drove many companies out of business. now concentrate on the needs of the
Product
Product • Prod-
The products a dealership sells are general- Quality is a major aspect of any product, Packaging is another key factor. This may
ly: new and used vehicles, financing, parts and this not only applies to parts and be obvious for many products sold in
and accessories, and servicing and repairs. accessories but also to servicing and repairs. shops, for instance accessories. But it also
Variety is important. The days when Ford applies to servicing and repairs. The tidy
But in marketing terms the “product” produced a Model-T in a single colour – appearance of dealership staff is as much
element goes beyond the product itself. black – are long gone. And a dealership part of packaging as the cleanliness of the
Because this is an article in Autoteam, today needs variety in his service offer, customer’s car when it is returned to him.
let’s concentrate on the Customer Service particularly in the way it is delivered.
aspects of the products. For example: by fixed time appointment,
on a while-you-wait basis, as part of an
overall package (e.g. winter check) etc.
autoteam 1•2000 13
P
• rice
Price
The importance of price is immediately Price competitiveness has become a major service delivery is inadequate. The obvious
apparent. But think of the various aspects factor as more and more independent service implication of the marketing element “place”
of price: the recommended retail price, outlets not only offer aggressive prices but is to think of your dealership facilities, the
discounted prices for specific customer also advertise them, making customers buildings and the furnishings. While this is
groups, special price offers, payment more aware of price offers. Value for mon- important, there’s much more to it.
methods (cash, cheque, credit cards), ey is an important consideration. A compet-
payment terms for fleet customers. itive price alone is not enough if product or
P
• lac
e
Place
Facilities: this covers a number of aspects – Parking: can a customer find a place to
not just the buildings themselves but the park his car when he arrives, does he have
furnishings, the cleanliness, the signage for to conduct a search when he picks it up
customers to find their way, a comfortable after servicing?
waiting area, convenience items (coffee,
magazines). It also refers to facility layouts
that support work processes, sufficient equip-
ment and adequate (parts) stock availability.
his car for servicing and not waste time to
Convenience of location. You can work get to his place of work, then the facilities
in the world’s most attractive dealership – themselves, as attractive as they may be
but if it’s too difficult for your customers to will not make up for the inconvenience.
find, too far away to make the trip worth-
while, too far out for the customer to leave
•
Pe
pl o-
e
Pe •
People op
le
If meanwhile you have begun to find the ■ Is the team spirit high enough to ensure ■ Customer handling – politeness, help-
topic of marketing so interesting, that you that all processes work perfectly in fulness and the general effort to demon-
want to dive deeper into the subject by delivering customer satisfaction? strate that the customer is valued by the
reading a standard textbook, the chances are ■ Are all employees fully motivated and dealership.
high that you will not find “people” as an proud of their dealership, so they speak
element of the marketing-mix. But it’s diffi- well of it and help build a positive dealer ■ Customer consulting – providing the
cult to imagine how the other four elements image? best possible advice to the customer in
can work without people. In this context we (Have a look at the article “The image all matters relating to his car; demon-
don’t simply mean people to do the job – impact” in this issue of Autoteam for strating customer care rather than
that doesn’t necessarily have to do with mar- more details.) employing hard selling techniques.
keting. But several “people” factors are in-
credibly important for successful marketing: Customer relations. Anyone with direct ■ Customer complaint management
customer contact will find it difficult to – taking customer complaints seriously
Employee relations. At first sight this imagine how any standard textbook could and doing everything possible to resolve
would appear to be a topic for the per- have missed this crucial aspect of mar- the complaint as quickly and efficiently
sonnel department and not a marketing keting. Possibly because it is less important as possible.
subject, except in the case of salespeople. in other industries but probably because it
But just think of these questions: has only gained so much importance in the ■ Customer convenience – ranging
past few years. As with the other elements, from appointment dates that agree to
■ Are all employees sufficiently trained customer relations also has a number of the customer to the provision of a
to deliver the service product to the components. courtesy car when required.
customer at the required quality level?
14 autoteam 1•2000
Promo
-
Promotion tion •
If everything you’ve read in this article up are enough examples of bad advertising – events in the dealership, sponsoring of local
to know worked perfectly in your dealer- good advertising can be very effective in activities (e.g. sports events) and generally
ship, you might think that promotion, for attracting new customers. all opportunities where a positive image of
instance in the form of advertising, would your dealership can be conveyed to third
be unnecessary, because word of mouth Point-of sale – posters, displays, parties (see “The image impact” article in
would be sufficient to draw in new cus- brochures in your dealership are all point this issue).
tomers. But let’s face it, perfection is rare. of sale materials. The key difference to
And there are potential customers out there advertising is that the customer is already
who would not be reached by word of in your dealership when he sees point of
mouth. Then you may have new, attractive sale material. So rather than attract the
offers to tell customers about. You may customer in the first place, this promotion
wish simply to remind existing customers makes the customer aware of other offers
how good a dealership you are. And there you may have and gives him more detailed
may be a need to respond to promotional information than is possible through
activities of your dealership’s competitors. advertising.
So promotion is important and, again,
there are a number of aspects to it. Public relations – a whole range of
activities with the aim of creating a positive
Advertising – the form of promotion that image of your dealership with the general
everybody is most familiar with. Whatever public. This covers articles in the local
you may think of advertising – and there press or mentions on local radio, customer
autoteam 1•2000 15
Crystal Clear Stig-Arne Mellerud,
managing director,
Røhne og Selmer
16 autoteam 1•2000
Monika Nemeth and
Klaus Rockstroh
demonstrating their
technical competence.
The youngest
Ford owner
Kari is a little girl, 15 months old. And, of course, we were happy to help. We hope Kari enjoys her new toy and we
She lives close to Bergneustadt An appointment was made with Uwe Lenke wish her all the best.
in Germany and is now probably and, on the day, Monika Nemeth – the
Europe’s youngest Ford owner – editor for non-technical articles – and Klaus Incidentally, before you even think about it,
although it’s not really a Ford. Rockstroh – responsible for technical the Transit shown on the cover of this issue
content – took the toy car to Bergneustadt. is not available as a present.
Unfortunately, Kari couldn’t be there on
You will the day, but her dad was more than happy
remember the to accept the car in her name. Of course,
picture on the Autoteam editors are highly service-minded.
front cover of So before handing over the car, they assem-
Autoteam 40, a bled it. This gave Klaus an ideal opportunity
little boy on a to demonstrate that he isn’t just responsible
toy car with a for our technical articles, but capable of
Ford logo on it. performing the most difficult technical jobs
himself. And Monika received first-hand
When Kari’s training on modern vehicle technology.
father saw the
cover picture, Uwe Lenke is a responsible father, and as
his immediate reaction was: “Great, that a member of the Ford world he is also
would be just the thing for Kari – at least quality conscious. So his suggestion to take
when she’s a little older. But how can I get the car for a test drive didn’t come as a
hold of the car?” Kari’s father is Uwe surprise. Powered by Autoteam editors,
Lenke, the Parts Manger at the Ford dealer- the car’s performance exceeded all expec-
ship in Bergneustadt: Friedrich Wilhelm tations.
Weil KG. He asked his Ford Zone Manager
for help, who then contacted the editorial All in all, an excellent pre-delivery inspec- Uwe Lenke test-driving Kari’s new car –
team. tion and a successful new vehicle handover. powered by Autoteam.
autoteam 1•2000 17
Lost your
bearings?
Would you drive around a
foreign country without
first studying a map? Surely it’s just the bulb ...
Of course not! So why do
some go about detecting
faults in vehicle electrics
in the same way – without
any sense of direction?
■ Table of Contents (always at the beginning of the manual) gives an overview of the individual
sections
■ The Systems Overview details which system can be found under which Chapter Number
■ The Index enables an alphabetical search of components
■ A short Introduction explains the Wiring Diagrams
■ The chapter Circuit Symbols gives a cross reference of symbols, wiring colours, circuit and
wiring identifications as well as circuit elements
■ The section Connector Repair Procedures shows repair instructions for faulty connectors.
■ The Wiring Loom Overview shows how the looms are laid out and where actuators are located
on the vehicle.
For very complex systems, an Overview Plan (Block Schematic Diagram) is provided. Problem resolved –
no more flickering.
18 autoteam 1•2000
Legend:
1 Part from component is shown
2 2 Component code
1
3 3 Component name
4 Pin number
Ford Focus Licence 5 Explanations of switch positions
Plate Illumination Circuit 6 Intermediate connector number
Diagram 7 Wire cross-section in square mm
5 8 Wire colour
(without daytime running lights)
9 Entire component is shown
10 Circuit identification code
11 Ground point number
12 Soldered joint
4 13 Symbol for electronic circuitry
7
6
8
10 between the two number plate bulb connec-
9 tors which now needs to be investigated
more closely. The wiring, which according
13 to the wiring diagram should be orange with
12 a black identification colour code, is in this
case Green ! To make matters worse, insu-
11
lation tape has been wrapped around the
wiring. Removing the tape reveals that two
For the purpose of this example, we have Fault example: wires have been pressed together. The reason
chosen a fairly simple diagram. Nevertheless, Whilst checking the exterior lights of a Focus for this: this car had recently sustained
it provides most of the important details of a you notice that the right hand number plate rear-end damage and had been “privately”
more complex wiring diagram. bulb does not light up, although it does and quite unprofessionally repaired.
Of course wiring diagrams (here in English) sometimes flicker briefly. The bulb is OK.
are available in all relevant languages. With the help of the wiring diagram and a Note: Ground current circuits are in basic
suitable meter, with the lights switched on, black (BK) – formerly they were brown (BN).
All wiring diagrams and explanations are permanent current at the connector C497
also on the TIS CD-ROM. can be checked. The reading is indicating 0 Layout and descriptions of wiring diagrams
Volts. Only when the number plate bulb is for American Ford products or niche
moved, there is an occasional current reading. vehicles, e.g. Maverick or Windstar, may
The suspected culprit is the wiring 29S-LF22 deviate from the European standards.
The current Ford Wiring Diagrams are broken down into 6 Sections Additional explanations
and Sub-Sections as appropriate:
■ The FSC circuit numbers are grouped
Section 1: General Information Section 4: Electrical into “Function” and “Wiring Identi-
fication” (FSC = Function System
00 Service Information 12 Climate control system Connection)
13 Instrumentation and
warning systems
Section 2: Chassis 14 Battery and charging
Function Colour
system
System-
04 Suspension 15 Audio systems Connection Wire-cross-section
05 Driveline 17 Lighting
06 Brake System 18 Electrical distribution Hints
11 Steering System 19 Electronic feature group In order to get the most from the Ford
Wiring Diagram manuals, the following
Section 3: Powertrain Section 5: Body and Paint instructions must be followed:
■ To enable quick access, mark the main
03 Engine 01 Body page and other important relevant
07 Automatic transmission 02 Frame and mounting pages with coloured stickers.
08 Manual transmission ■ The page numbers shown above enable
and clutch Section 7: General Wiring Information fast orientation within comprehensive
09 Exhaust system chapters such as “Ground connections”.
10 Fuel system 00 Fuses, relays, current ■ Note important information (references)
distribution, connector such as wiring identification codes,
views, component connectors, cross references, etc., so
that you can concentrate totally on the
Example: Wiring diagrams of the exterior lighting are found under Section 4, Sub-Section 17. actual fault detection procedure.
Turn to Chapter 4 17 in the manual.
autoteam 1•2000 19
The Service Advisor
gives his customer an
important tip.
20 autoteam 1•2000
1. From the registration document he knew that the Mondeo
was three years old. Jörg cleans all
2. Yvonne had shaken her head in surprise when he asked connections
whether she also regularly switched the air conditioning before remov-
system on during the colder months of the year. ing the dust
3. After a visual check and a test run he had the impression caps.
that the system including compressor, auxiliary fan and air
flaps were functioning correctly. The on-off cycles
appeared, however, to be too short.
And so he completed the repair order like this: Probable
normal loss of refrigerant; visual check, compression test, fill
check, top up as necessary.
Normal leakage
“Let’s check how much is still in the system”, suggested Jörg
and switched the Servicing Unit to draining. When this was
done we read 0.48 kg. Far too little, because the A/C label, on
the hood lock crossbar of the Mondeo, stipulates 740 +/– 15 g
refrigerant type R134a. Jörg showed us that according to
the Vehicle System Test Manual this quantity of lost fluid is
normal for a vehicle of this age.
autoteam 1•2000 21
The rest was routine: Evacuate the system, vacuum test, refill,
As expected, and pressure test again. Everything was in order. Workshop
a lot of the Foreman Alfons Ohlinger came to check the repair. He mea-
refrigerant sured the air outlet temperature at the centre face level vent:
fluid is missing: OK. Finally Alfons checked all visible connections of the
Nominal system with the UV Leak Search lamp: No visible leakage.
amount: Finished!
740 g +/– 15 g.
Clarification
When the customer came to collect her car, the Service Advisor
could confirm that there was no real damage and “only” a
refrigerant fluid top up had been necessary. Using the Owners
Manual of the Mondeo, Maintenance and care section, he
explained how she could influence the refrigerant consumption:
“The air conditioning system should be used monthly for at
least 30 minutes.” “In winter as well?”, Yvonne asked sur-
prised. “Then too. When in use the refrigerant oil circulates
Leak detection through the system and improves the sealing. A certain loss
fluid is poured of refrigerant is unavoidable after several years, but this is
in. substantially reduced by keeping the seals well lubricated.”
Yvonne was thankful for the tip and relieved that the damage
was not greater. Now she could await the hot spells of the
year with a cool mind.
Final check:
the Workshop
Foreman
measures the
Indispensable
temperature at
the centre face- Vehicle System Test Manual and Training
level air vent.
An indispensable aid for the diagnosis and repair of air
condition systems is given in Section 34B of the Vehicle
System Test Manual. In the case described here the
following chapters were consulted:
22 autoteam 1•2000
Normal!
The most frequent misunderstandings
Not every customer concern is a workshop is enough to explain to the customer that what The most frequent “explainable” concerns with
case. Often a look into the Owners Manual they thought was a malfunction is quite normal. air conditioning are shown below:
Concern Explanation
Rapid clicking sounds at high The switch cycle times of the compressor are very short at high ambient temperatures. The on-off switching
ambient temperatures. results in clicking noises that are sometimes a cause for concern, but are quite normal.
The air conditioning system doesn’t The system is automatically switched off at temperatures close to freezing (usually below 4° C). The switch-off
work at low temperatures. temperature in Galaxy is 5° C and the system is activated again at an ambient temperature above 8° C.
Air conditioning systems extract humidity from the incoming air that is then drained off as condensation via a hose under-
A pool of water gathers underneath
neath the vehicle. If the air conditioning is switched off a few minutes before the end of a trip the condensation can evapo-
the vehicle.
rate within the system. This also helps to avoid the pungent smell which can sometimes be caused by condensation.
The air conditioning system The air conditioning in vehicles with semi-automatic systems is activated automatically when the air vents are
switches itself on. set to de-mist the windscreen. The system switches automatically to “outside air intake” to maximise this effect.
The above cannot claim to be comprehensive rence of the particular system. This is especially ment of a fault. Since the supposed fault cannot
and symptoms can vary with different models. true when the customer is driving a vehicle with subsequently be rectified, the customer – partic-
But this rule applies to all: Make sure before- air conditioning for the first time. If you treat ularly within the guarantee period – could claim
hand that there really is a defect or whether the such a normal occurrence as a “repair”, then you have been unable to repair their vehicle.
described “Phenomenon” is a normal occur- the customer will take this as an acknowledge-
Investing today in tomorrow ... “Autohaus am Verteiler is part of the The dealership’s
... could briefly summarise the company Heister Group with altogether 9 dealer- success proves
philosophy of “Autohaus am Verteiler”. ships. It is this co-operation with the other Herr Juerges
And this does not just apply to the dealerships which enables us to not only right. Since
planned new building on Trier’s northern take on our apprentices at the end of their taking over the
main in-bound road, in which they plan training, but also to offer our employees parent firm at
to continue the past success of the busi- opportunities for advancement”, Rudolf Trier’s motor-
ness in new settings. It also applies to the Juerges, Commercial Service Manager of way junction in Commercial Service
training of apprentices, which is tradition- the Heister Group, told us. 1979, the com- Manager
ally a major objective of this company. pany has been Rudolf Jürges
“We make high demands on our able to take
employees, we offer, however, high over or open further dealerships. Today
prospects in return” he continued. customers enjoy comprehensive service
“Our lean organisational structure throughout the entire group, from new
with clearly defined areas of responsi- vehicle sales to maintenance, from body
bility makes it possible to give our and paint repairs to financing, leasing, car
employees a high level of freedom in rental and insurance. The company even
their decision making. I think, this publishes its own customer information
is one of the reasons for the high magazine.
motivation and dedication to perform
The “Autohaus am Verteiler” Service Team. well in our company.”
autoteam 1•2000 23
The most common cause
of injury at work is slips
and trips.
There are two aspects to this, keeping you the seats cannot be allowed. Fortunately, able gloves when doing dirty jobs. Get into
clean and keeping your work area clean the latter can be easily avoided by using the the habit of washing your hands regularly –
and tidy. Both have equal importance. various protection products available – e.g. before putting on personal protective
We’ll start by looking at you. seat covers. But you aren’t doing yourself equipment, before meals and before and
any favours by allowing your skin to after using the toilet. Similarly, wear over-
Personal cleanliness become contaminated with workshop dirt. alls while at work but change them straight
There are obvious reasons why you should Skin is very good at absorbing whatever is away if they become contaminated. Always
keep as clean as possible while at work. placed on it. Bad news if that substance remove dirty overalls before eating. This
The first is the customer, or more specifi- happens to be harmful. may seem excessive, but good hygiene is
cally the customer’s vehicle. Fingerprints on essential in order to reduce health risks
the paintwork, inside the vehicle, or even It is always a good idea to protect your such as skin cancers. Never put oily rags in
worse dirt transferred from your overalls to hands with barrier creams and /or dispos- your pockets!
24 autoteam 1•2000
Avoid contact, where possible, with sub-
stances that are known to cause problems:
oils, coolants, greases and solvents. Use
gloves when working if this is possible but
ensure that you use the right sort of glove
for the job – one designed to protect you
from abrasions when changing an exhaust
may not protect you from solvents. If you
are doing a job where your face might get
splashed use a splash guard or face shield.
Used engine oil can harm skin so avoid
coming into direct contact with it. When
you drain an engine of oil, wear latex
gloves and, if possible, use an automatic
oil refilling system.
autoteam 1•2000
25
The image impact
Imagine you’re on your way to the calm the patient down, but with ment, the situation changed completely.
dentist. Just before you enter his that treatment, there’s not much First of all, the assistant’s statement implies
office, an acquaintance of yours I can do about it.” that the pain was not a normal side effect
steps outside – obviously in pain of the treatment, but that something went
– and complains how much the It’s not difficult to imagine your wrong. In addition, she said that this was
treatment hurt. This probably reaction to a situation like this: not an isolated case, but something that
doesn’t make you feel much hap- you would most likely say good- happens often. And finally, you heard it
pier about your own treatment, bye to the assistant, leave the from an “expert” – who would know
but it’s unlikely that you would office and look for another den- better than a dentist’s assistant, whether
turn around and go back home. tist. or not the dentist is fully qualified – and
You then enter the office and are because an “expert” made the statement,
greeted by the dentist’s assis- The reaction it was very credible.
tant. You mention that you just Let’s have a closer look at what happened here:
met your acquaintance outside When the acquaintance complained about A ruined reputation
and that his treatment was the pain, this did not create a terribly nega- The natural reaction: you look for another
obviously very painful. Now just tive impression. After all, dentists and pain dentist. But it’s more than that. You would
imagine the assistant’s response go hand in hand for many people. And certainly tell your family and friends about
is like this: toothaches are generally painful. The fact it and they certainly would never try this
that an individual patient left the dentist in dentist. Furthermore, they would mention
“Unfortunately, that’s quite pain said nothing at all about the dentist’s it to others and the word would spread.
normal. The doctor often has qualification. The consequence could easily be a ruined
difficulties with that kind of treat- reputation for the dentist.
ment and then it’s very painful. But when the assistant explained that the
Of course, I personally try to doctor often has difficulties with a treat-
26 autoteam 1•2000
You may well think that in such a situation anyway. But what about relatives, friends, In most cases, that is a myth. Of course
a ruined reputation is just what the dentist and acquaintances? Nothing is more some companies are better than others,
deserves. But is that really true? All you commonplace than to complain when but perfection is difficult to find. Generally
were told is that the dentist “often has something goes wrong, simply because it employees are simply more familiar with
difficulties with that kind of treatment”. helps to relieve one’s own frustration. the things that go wrong in the company
You don’t know what treatment it was, you they work for than with the mistakes that
don’t know how often such a treatment is Things to be aware of happen in other companies.
carried out, you don’t know how difficult it You’ve probably heard other people com-
is and – above all – you don’t know if any plaining about their job, the company they Someone is always to blame
other dentist could do it better. It could, work for, the products they handle or the Most of the time when you feel like
after all, be a treatment that is very rare, suppliers they deal with. And, frankly commenting on something that has gone
extremely difficult and generally very spoken, it would be surprising if – at least wrong, it’s not because you yourself have
painful, regardless of which dentist carries occasionally – you didn’t feel like com- made a mistake,
it out. plaining yourself. There can be many but because someone else has. And when
reasons for this and it’s important to be that happens, it’s perfectly natural to want
So, in reality, a few sentences thoughtlessly aware of them so you can put them into to tell someone about it. And if you are
spoken by the dentist’s assistant – an perspective. confronted by somebody who had prob-
“expert” – could ruin the dentist’s reputa- lems because of this mistake, it’s very
tion, although he may be one of the best in The downside of Service tempting to explain that it was really some-
his field. Working in the Customer Service depart- one else’s fault.
ment of a dealership – as in service areas
within other industries – does have one dis- This doesn’t mean you blame an individual
advantage: you are often confronted with person. But it’s often easy to blame the
things that need to be repaired. Except for a computer, the administrative department,
routine service, where no cause for repair or the supplier, the product or something else.
replacement is found, or when an accessory Again, a perfectly human reaction – but not
needs to be installed, customers come to one that is good for business.
you because a repair is required. This means
you see more things that need fixing than Where it all comes together
anybody else in your dealership. An example where all the above factors
come together is a product concern with a
And the fact that customers don’t normally
enjoy bringing in their car in for a repair
doesn’t make life any easier.
In comparison to a job where one is never
confronted with product concerns or un-
happy customers, your inclination to be
critical about the products you deal with is
naturally much greater.
There are many opportunities for a wrong In fact, in most businesses, the employees
choice of words. Words that can endanger of a company are all too aware of the
the image of a dealership, of Ford products things that could be improved in their
or of Ford. Perhaps you feel that it’s un- company and believe that, if only they
necessary to mention this, because you worked somewhere else, they would not
never say anything wrong to a customer be confronted with so many difficulties.
autoteam 1•2000 27
is that vehicle quality has increased so Remember, where cars and the dealership
significantly. you work for are concerned, you are an
expert and your words carry greater weight
The impact on image than you may believe.
A positive image is one of the most impor-
tant assets a company can have. It takes a
long time to build a positive image, one of
the reasons being that good qualities are
less frequently talked about than company
deficiencies. But a good image can rapidly
be destroyed – not necessarily because the
company is performing any worse than
others, but merely because it suffers from
customer’s vehicle. You’re faced with a negative publicity.
specific problem, possibly not for the first
time, you feel that the concern should have And publicity doesn’t just refer to words in
been resolved earlier in vehicle production the press or other media. Publicity can be
or – even better – not have occurred at all, achieved merely by a
you believe that another vehicle manufac- series of conversations
turer would have avoided this concern between different peo-
altogether, and the possibility of putting ple. And a conversa-
the blame on Ford – maybe even in front tion you have with a
of the customer – may be tempting. relative, a friend or a
customer can impact
Of course things can go wrong in the the image of your
design or production of a vehicle. Modern dealership, Ford prod-
cars have become so incredibly complex ucts or Ford itself.
that this is very difficult to avoid comple- Because whoever you
tely. And this applies to all vehicle manu- talk to may tell some-
facturers. If you think other manufacturers one else about it, who
are substantially better than Ford, just ask in turn may again
yourself why their dealerships need service repeat it to other
workshops – surely not just for routine people, and so on.
servicing and wear and tear repairs. This image impact can
be positive or negative
And remember that, in spite of the increased – it all depends on the
vehicle complexity, the major reason why views that you express
customers visit your workshop less often, initially.
28 autoteam 1•2000
TSB résumé
Section: 41 (501-03) Section: 00 (100-00) Section: 45
No: 16/2000 No: 19 No: 22
Model: Focus 3-/5-door and wagon, Model: Fiesta 2000.5 MY Model: All
built up to 09.99 Subject: Colour codes
(build code XJ) inclusive Subject: Introduction of new Fiesta
The attachments to this bulletin contain
Subject: Rattling, cracking or knock- This bulletin introduces the 2000.5 MY details of the exterior colours used on
ing noises from the tailgaste when driving Fiesta and contains information relating Ford vehicles, including special colours,
on uneven road surfaces to new and updated vehicle systems and sorted according to various criteria. In
Service Literature. Please familiarize most cases the English name for the
Should a customer express concern yourself with this information to make colour is used.
about these noises when driving on sure that a high level of customer service
uneven road surfaces, the cause may be is provided.
contact between the various components
in the tailgate area or insufficient noise
damping material, depending on vehicle
variant. This TSB explains, how to
reduce these noises.
Competition
Keys The Sales Manager asks the apprentice to identify which key fits
to which car. What is the number of attempts to unlock the cars
Two trucks arrive at a dealership to deliver 14 new cars. The that is needed to match the keys to the cars with 100 % certainty,
truck drivers take all cars to the dealership’s new car storage if the apprentice is not helped by luck?
area, lock them and hand the 14 keys over to an apprentice at
the dealership. The keys are unmarked, do not have remote All those who return their answer cards after answering the
control and look identical. questions set in this issue are eligible to enter this competition.
autoteam 1•2000 29
Confidence: Test data is permanently
stored and can be clearly transmitted
without misunderstanding.
Have you
ever seen
this...?
Diagnosing a fault is one thing
but fixing it is another. This is
when the exchange of knowledge
and experience can be invaluable.
WDS, Ford’s Worldwide Diagnostic
System, can store test results
permanently so that they can be
transmitted to remote locations
for help and advice. In addition,
completely new data can be
uploaded directly from Ford.
Misunderstandings guaranteed: Complex information on the screen cannot easily be
described.
The example of the ignition voltage test Worth more than a thousand words be available for as long as necessary.
described in the last issue of Autoteam, So you call and describe your problem: The WDS test unit (PTU) can store test
demonstrated how fast running processes “Have you ever seen this ...?” But the infor- sequences, but with intensive use of the
can be recorded using the memory storage mation you have on screen and staring you PTU that test data will soon be overwritten.
function of WDS for later step-by-step in the face, is not that simple to describe You need, therefore, to save your test data
review (“Recording” by Camera icon). verbally. Misunderstandings are the result; to a permanent storage medium. How you
your problem isn’t resolved but gets even should do this is explained in the panel
You know then exactly “what” occurred more complicated. What can you do? Easy: “This is how it’s done”.
and “when”, you need only to find out transmit the diagnosis report to your helper
“why”. If the problem you are working on for him to check it out on his own PTU. For later use
proves to be a particularly difficult one And as the screen “picture” is worth more Permanent Storing of test routines can also
however, one that you have never encoun- than a thousand words, between the two of be useful in other instances:
tered before, then you may want to learn you, you’ll soon find the solution. ■ You call for help, e.g. the Technical Hot-
from the experience of a “wise” colleague line: Your (stored) test routine should be
in another dealership – why not –, or you Permanent storage readily available so that you do not have
call up the Ford Technical Hotline. But in order to transmit test data, it must to report from memory.
In the Network
If your WDS is integrated into your Programming software (not WDS soft-
company’s computer network, not ware). Or Ford engineers can call up
only can you enjoy the benefit of certain WDS error codes from the
printing out test reports on a central dealer network for field investigations
printer, but you can also make the – subject of course to prior agreement.
test data available to a PC or another
WDS. *) CDS (Company to Dealer System)
is the network system through which
CDS the dealer organisation has access via
Your WDS can also be connected the Internet to Ford’s Extranet, and so
on-line with Ford’s main computers to Ford computers and systems.
if your dealership is linked into the
Ford CDS Network*). Then Ford can
provide you with the newest PCM
30 autoteam 1•2000
■ You’ve found the fault, but have to wait
for parts before you can carry out the This is how it’s done
repair. When you go back to complete
the repair, you have the test report avail- Recording and storing, e.g. Ignition
able again. voltage test
■ You want to compare the test results of
your “patient” with those of a “healthy” 1. Click the “Camera” icon (Recording) top
right; several times for several recordings.
vehicle without having both in the work-
Click the “Movie” icon (Playback) in the
shop.
bottom tab row. Use the arrow keys to
■ A problem you are working on seems switch back and forth between the different
familiar. You can call up the stored test recordings. The number of recordings is
data of previous cases for comparison. shown below right.
You can even create a whole library of
2. Click the “Select Systems Options” icon
interesting cases. (top right): “Save recording group” [Save
recording group].
Datalogger
3. Assign description – Keyboard screen –
Permanent storage of WDS data is of
“Enter Description” [Enter Description].
invaluable benefit, for example when per-
forming dynamic measurements through 4. Select recordings to be saved [Select
recordings to saved] and acknowledge.
the Datalogger. (Autoteam will dedicate a
detailed article on the Datalogger in a later 5. Assign description to Recordings Group
issue.) This tool in particular requires [Recordings Group] if necessary (keyboard
experience, which can be gained through screen) and acknowledge.
comparisons and exchange of information 6. Click the “Terminate Session” icon
with colleagues. (bottom left), select “HOLD” [HOLD]
and acknowledge. Important: The data
captured can only be stored permanently
if the “HOLD” option is used to exit from
the vehicle (The PTU can store a maximum
of ten “held” sessions).
7. Connect the PTU to the Docking Station
and insert a floppy diskette into the
Despatch docking station’s diskette drive.
8. In the Vehicle Selection menu (Entry screen)
Of course you can send a WDS test data select “Previous Sessions” [Previous
diskette by mail. But once the data from Sessions] and acknowledge.
WDS is stored on your PC, you have 9. Select from the list “Held Sessions” [Held
many quicker methods of electronic data Sessions] the session which is to be stored.
transmission at your finger tips. 10. Click the “Save to diskette” icon, archive
session (this icon appears only, if the PTU
Elegant is in the Docking station). Wait for “Files
The most elegant method of despatch Archived” acknowledgement [Files
is to send an e-mail with a detailed Archived].
description of the fault to your helper 11. File the diskette, send it via post or load to
and simply attach the file containing the PC for transmitting, e.g. by e-mail.
WDS test data.
Loading from diskette
Don’t worry: You can’t view WDS files 2. Click the icon “Load from diskette”.
on your PC. WDS stores only core data 3. Select the vehicle or the test from the list
in a special format and not the back- [Select recording group to load].
ground data, which is programmed into 4. Click the “Ignition Test” icon, then the
each WDS to enable screen display. Thus “Movie” icon.
the quantity of data remains small, fits
5. Call up test recording(s).
onto a 3,5” Diskette and can be trans-
mitted at high speed. Note: Screen texts are shown here in English.
WDS will of course show these in the selected
language.
autoteam 1•2000 31
Ford Facts
The numbers alone are staggering – more than 105,000 Today, Ford is still ahead in safety. The “total design”
dealers in over 200 countries; manufacturing, assembly philosophy offers standards that meet and often exceed
and sales operations in over 30 countries; backed by Ford test requirements all over the world. In fact, some of
Credit, Europe’s second largest finance company with Ford’s current standards will exceed individual countries’
over 1.2 million customers. future requirements.
However, numbers tell only part of the story, especially in And Ford also leads in protecting the environment. The
technology. We all know that with the Model T in 1913, company introduced the world’s first recycling design
Henry Ford introduced the very first production line, but guidelines to help maximise conservation at every stage
other innovations are less well known, even though they of the design and manufacturing process. Ford is also a
were copied by the entire industry. leading supporter of the European Conservation Awards,
and has been awarded over 125 patents for innovations
For instance, the first car radio came in the Ford Model that reduce emissions, improve catalysts and sensors,
T in 1912, which was also the first car to reach control fuel vapours and increase efficiency.
1,000,000 models in production only three years later.
Ford also sets new standards in fuel management with
In 1959, Ford was the first automotive company with more cars that run on alternative fuels than any other
computerised design and manufacture, and the idea that manufacturer. And it was one of the first organisations
a car could be both strong and light, like an aircraft, was in the world to achieve the worldwide environmental
introduced only 3 years later on the original Cortina. The standard of ISO 14001 for manufacturing.
computerised approach reached its peak with the Puma,
the first Ford car ever to have been designed entirely on To ensure the company stays in the forefront of innova-
computer, resulting in a record time-scale for designing a tion, the Worldwide Engineering Release System enables
new car – in just four months Ford engineers to exchange information with their
colleagues on four continents. Believed to be the world’s
From the introduction of safety glass windscreens on the largest privately owned database, the network provides
Model A in 1928, the company has also been a leading essential manufacturing and design data.
innovator in safety. Ford pioneered crash testing in 1951,
appointed the first full-time Product Safety Engineer a Add a remarkable record in product awards with the
year later and introduced the first cars with both front Focus in 1999 – the most recent of four cars to be named
and rear seat belts in 1955. European Car of the Year – and hundreds of other awards
in the past, Ford’s track record of originality and ingenuity
ABS has been a particular speciality – in the mid-1980s, is well proven. And it is this commitment to continuous
Ford designed the first ABS system specifically for front- innovation that will no doubt keep Ford at the leading
wheel drive cars such as the Escort and Orion. It was the edge of automotive technology in years to come.
IRL