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Ford Eltec

The Ford Eltec was a research and concept vehicle built by Ford, with its name standing for "Electronic Technology." It was developed jointly by Ford's Research and Design departments in England and West Germany and was built in less than eighteen months, a short period given the amount of new technology it incorporated. The car made its debut at the Frankfurt Motor Show in 1985 and was presented as an exploration of vehicle electronic management systems intended for the twenty-first century. Ford described it at the time as demonstrating "the technology of the family car of the nineties," aiming to show how electronics could serve both drivers and the environment. It was a five-door, front-wheel-drive family saloon with a fastback-style body seating five people, and it foreshadowed styling elements later seen on the following generation of the Escort, launched in August 1990, with which it shared numerous stylistic parallels.

The Eltec's development programme sought to combine optimized driving performance, safety, reduced environmental impact and comfort through electronics extended well beyond the ignition, injection, driver information and early ABS systems typical of the mid-1980s. It applied electronic control to engine management, a continuously variable transmission, suspension tuning and a combined ABS/traction control system. At the core of the car's control architecture was the Ford EEC-IV microprocessor, described by Ford as having "the power of two personal computers," the same unit already used in the Scorpio. Unlike conventional cars where engine and transmission computers operated separately, the EEC-IV in Eltec treated the engine and transmission as a single powertrain system, coordinating performance, drivability and fuel economy continuously.

Power came from a specially built 1.3-litre, four-cylinder, light-alloy, wet-liner engine with 12 valves (two inlet, one exhaust per cylinder) and a chain-driven overhead camshaft, producing 80 PS (59 kW) at 5000 rpm. It ran unleaded fuel under a lean-burn concept at a 20:1 air-fuel ratio, compared with the standard stoichiometric ratio of 14.7:1, and achieved this output with fuel consumption around 40 percent lower than conventional engines of the period. Torque exceeded 120 Nm between 2500 and 4000 rpm. The crankshaft bearings were housed in a separate bedplate to strengthen the block and reduce vibration.

Several electronically controlled features improved combustion efficiency. An expansion chamber shortened the effective length of the intake tracts at higher engine speeds, while sliding tubes gave a dual inlet manifold system: a longer tract length for strong low-speed torque, switching above 4000 rpm to a shorter configuration for better volumetric efficiency at high revs. Each cylinder had two intake ports; at low loads and speeds, only a "primary" port was used, with the second activated as demand increased, and swirl-inducing blades in the primary port improved mixture quality at light loads. Ionisation feedback sensors mounted opposite the spark plug in each cylinder monitored the combustion flame front, feeding data to the EEC-IV so that ignition and injection timing could be fine-tuned continuously for temperature, altitude, fuel quality, manufacturing tolerances and component wear. An electronic throttle replaced the mechanical link between accelerator pedal and throttle butterfly, using a potentiometer to signal driver demand to the EEC-IV, which then determined the optimal throttle and transmission ratio combination; this system also supported cruise control and traction control functions. Exhaust emissions were further reduced through a two-way oxidation catalyst and exhaust gas recirculation.

Cooling was managed by a dedicated system in which coolant spaces in the cylinder head and block were linked only by bleed holes, allowing tighter control of head and valve temperatures while raising cylinder wall temperature to cut bore friction. An electric pump circulated coolant, with the EEC-IV increasing pump speed and activating twin electric cooling fans as needed. The resulting cross-flow radiator was 30 percent smaller than the Escort's. Cooling air entered through an aerodynamic duct in the front bumper, and at higher speeds five rubber flap valves opened automatically to draw out surplus hot air, closing again when the car was stationary. This arrangement let the engine reach operating temperature faster, reducing both fuel consumption and emissions, while a heat shield around the exhaust helped the catalyst warm up more quickly.

Drive was sent through a new continuously variable transmission, a belt-and-pulley CTX unit representing an early version of the CVT technology later used by Ford, Fiat and Subaru. The EEC-IV controlled its ratio according to two selectable modes, "Power" and "Economy," adjusting engine speed and available power accordingly, and also managed the clamping pressure between the transmission sheaves and drive belt to minimize losses.

The suspension used electronically controlled air springs with hydraulic dampers, forming a self-levelling system that also adjusted damping stiffness automatically. Sensors and an electronic control unit detected conditions such as hard cornering, sharp braking, acceleration and high speed, switching the suspension from a soft comfort setting to a firmer one as needed, while at speed the car's ride height was also lowered to reduce drag. A separate low-cost electronic system combined wheelspin control with anti-lock braking, developed with Kugelfischer using standard braking components together with an electronically controlled power servo, giving an effect similar to a limited-slip differential.

The car was fitted with Uniroyal's newly developed run-flat tires, which could not come off the rim even after a complete loss of pressure, paired with an electronic tire-pressure monitoring system that gave a dashboard warning if pressure fell below a minimum threshold; as a result no spare wheel was fitted. Wiring throughout much of the car used a multiplex system, replacing the traditional wiring harness with a simplified two-conductor arrangement and a central electronic unit handling signal input, logic, processing and transmission, in contrast to a typical early-1980s mid-size car's wiring loom of around 850 meters of cable in 12 gauges, 49 color codes and roughly 950 connectors.

The body, aerodynamically shaped with a drag coefficient of 0.31 and surrounded by prominent impact protection, was designed by Ford of Europe and built by Ghia in Turin. New headlamps developed with Hella used a projection principle similar to a slide projector lens, giving even road illumination with a sharp light/dark cutoff that reduced glare for oncoming traffic and for the driver in fog, while allowing smaller lamp housings suited to the car's aerodynamic nose. Some tail lighting was relocated into the rear roof rails. The glass sunroof was made up of five louvred glass segments that could be tilted up or slid back; they returned automatically to their base position after the ignition was switched off but remained tilted, with a rain sensor triggering full closure when needed. Inside, the cockpit carried a substantial array of analog instruments and gauges, designed to be ergonomic and functional rather than futuristic in appearance.

The Eltec measured 412 cm in length, 164 cm in width and 136 cm in height, with a wheelbase of 259 cm and a track of 142 cm. As a research prototype, it was never put into production, but several of the technologies it previewed, including CVT transmission concepts and elements of its electronic engine management, informed later production Ford models.

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