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I am going in this afternoon for the PCM update. I will use this thread to post my observations after the update.

We've noticed something strange on this road trip. After we spend a long time driving on the freeway the car behaves strangely once we start driving in the city. Normally when I accelerate in the city the ICE comes on and revs up to about 2k RPMs when the power bar is at the 2nd bar on the Empower screen. After driving many hours on the freeway at 65-70 MPH when we come into a city and are accelerating away from a traffic light the ICE has been revving to about 3k or 3500 RPMs when the power bar is at the same level on the Empower screen. Turning the car on and off has not made any difference. But then after the car sat overnight it has been fine the next morning. We saw this when we first got to Winnipeg and attributed it to a one time fluke. But then it happened again when we got to Calgary yesterday evening. And then the car did it again last night when we got to Edmonton. In Calgary and Winnipeg it didn't fix it turning off the car and restarting it. In Edmonton after a few traffic lights of stopping and accelerating the car fixed itself and began behaving normally. We also saw this behavior in some of the small towns that we drove through along our journey. In Canada, unlike interstates in the US, the Trans-Canada highway goes through all the small towns and slows down to 50 kmh (about 30 MPH) for every town with traffic lights in each town. Has anyone else experienced this strange behavior? I am wondering if it is because of my grille cover, but I don't have any credible idea of why the grille cover would cause this. One theory is that the car is learning the highway driving pattern and for some reason is thus revving higher in the city than normal, but I don't know if that makes any sense. When cruising at 65 MPH the RPM is right about 2k exactly.

So far this is my best single trip mileage I have recorded 44.7 mpg. Most of those 36 miles is on the interstate at 65 mph as well. Keeps getting better and better as it breaks in! :shift: :dance:

Ford Fusion Certified As America’s Most Fuel-Efficient Midsize Sedan All-new Ford Fusion is America’s most fuel-efficient midsize sedan after being certified by the U.S. Environmental Protection Agency to deliver 47 mpg city, 47 mpg highway, 47 mpg combined in hybrid model Ford Fusion Hybrid beats Toyota Camry Hybrid by 8 mpg highway, 4 mpg city New Fusion offers greatest powertrain range of all midsize sedans with five engines, including two EcoBoost® options and hybrid and plug-in hybrid variants for true power of choice Ford Fusion Forum – The all-new Ford Fusion is the most fuel-efficient midsize sedan in America with an EPA-certified 47 mpg city, 47 mpg highway and 47 mpg combined fuel economy rating for its hybrid model. Fusion Hybrid tops the Toyota Camry Hybrid by 8 mpg highway and 4 mpg city, and delivers the highest-ever fuel economy numbers in city and highway driving for a midsize sedan. “The new Fusion is part of our plan to offer vehicles with the very best quality, fuel efficiency, safety, smart design and value,” says Alan Mulally, Ford president and CEO. “We are absolutely committed to class-leading fuel efficiency as a reason to buy Ford vehicles, with customers able to choose the fuel-efficient powertrain that best fits their lifestyle.” Power of choice: Two EcoBoost engines, one hybrid, one plug-in hybrid The all-new Fusion brings the widest range of powertrain options to the U.S. midsize segment. Fusion offers hybrid and plug-in hybrid variants and two fuel-efficient EcoBoost® four-cylinder engines for customers. In addition, Fusion is available with Ford’s patented Auto Start-Stop system, which automatically shuts off the engine at stationary idle to help save customers even more fuel in stop-and-go city driving. Fusion is available in front-wheel-drive and all-wheel-drive configurations with both six-speed automatic and six-speed manual transmissions. “Ford is bringing power of choice to midsize sedan buyers,” says Mark Fields, president of The Americas. “More than 2 million customers this year will purchase midsize cars. Our new Fusion delivers the fuel savings people truly want and value, with technologies that cost two to three times the price on some German sedans.” Fuel economy numbers for the remainder of the Fusion lineup are: 1.6-liter EcoBoost: 25 mpg city, 37 mpg highway, 29 mpg combined 2.0-liter EcoBoost: 22 mpg city, 33 mpg highway, 26 mpg combined 2.5-liter: 22 mpg city, 34 mpg highway, 26 mpg combined Fusion Energi plug-in hybrid: Projected 100-plus MPGe (miles-per-gallon equivalent) The Fusion equipped with the 1.6-liter EcoBoost engine is available with Ford’s patented, fuel-saving Auto Start-Stop system, which smoothly shuts off engine power when the car is stopped and seamlessly restarts as the driver releases the brake pedal. This feature, available for just $295, improves fuel efficiency by 3.5 percent and reduces emissions. Fusion Hybrid features two additional innovations to help deliver industry-best fuel efficiency: Ford’s patented SmartGauge® with EcoGuide that coaches drivers for top fuel efficiency; and ECO Cruise, a greener cruise control functionality that helps optimize powertrain elements for convenient yet economical highway travel. Fusion Hybrid achieves a top speed of 62 mph in electric or EV mode and also has Active Grille Shutters, which make the car more aerodynamic at highway speeds to improve fuel efficiency. An underbody with aerodynamically designed panels provides even better fuel efficiency. World-class craftsmanship, driving dynamics The full Fusion range delivers visual quality through improved materials, elevated levels of craftsmanship and attention to detail. To deliver its world-class driving dynamics, Ford engineers equipped Fusion with a specially tuned electric power-assisted steering system, MacPherson strut front suspension and all-new multilink rear suspension that is comparable to the setups found in more expensive Audis and BMWs. “Fusion is a driver’s car,” said Raj Nair, group vice president of Product Development. “We have carefully tuned this car to reward the driving expert and flatter the novice.” Ford’s quietest midsize sedan ever, Fusion Hybrid models are equipped with Active Noise Cancellation, which uses the audio system to mitigate powertrain noise. Technology you can use The all-new Fusion offers an unprecedented portfolio of driver assistance and convenience technologies using sensors, cameras and radar to enable the car to “see” and respond. Fusion can help drivers maintain proper lane position, adjust vehicle speed to changing traffic conditions, identify suitable parking spaces and practically park itself – it can even aid drivers backing out of a parking space in which visibility is obstructed. Specific technologies include: Lane-Keeping System: Using a small, forward-facing camera behind the inside rearview mirror, this system “looks” down the road, monitoring lane lines to determine that the car is on course. The system will alert a driver if drowsiness or erratic lane-keeping is detected. The second element warns a driver with a steering wheel vibration if the Fusion drifts too close to lane markings. Finally, Lane-Keeping Aid will actually apply pressure on the steering to help bring the car back into proper lane position Adaptive cruise control: Using forward-looking radar, this system “looks” down the road when activated, slowing the Fusion when slower traffic is detected ahead. The system can help slow the car if the potential of a crash is detected Active park assist: Employing sensors, this technology identifies a suitable parallel parking space, calculates the trajectory, and steers the car to properly position it within the spot. Drivers operate accelerator and brake pedals BLIS® (Blind Spot Information System) with cross-traffic alert: Sensors in both Fusion rear quarter-panels are able to detect traffic in a driver’s blind spot, providing both audible and visual warnings if traffic is detected. BLIS technology enables cross-traffic alert, warning the driver of oncoming traffic when backing out of a parking space with obstructed views, such as between two large vehicles The all-new Fusion also offers the newest version of Ford’s award-winning SYNC® communications and entertainment system, which enables voice-activated communication through a driver’s mobile phone and interaction with the car’s audio system. Fusion is available with the latest version of MyFord Touch®, allowing a driver to interact with vehicle systems through voice control, a touch screen tap or a conventional button. Both SYNC and MyFord Touch – powered by SYNC – help reduce the potential for driver distraction through voice-controlled functionality, allowing drivers to keep hands on the wheel and eyes on the road. Fusion equals growth The midsize car segment is the fastest-growing segment in America this year. Overall U.S. industry sales are up 15 percent in 2012, while midsize car sales have grown 26 percent. To meet expected demand for the new Fusion, Ford is adding 1,200 hourly jobs and investing $555 million at its Flat Rock Assembly Plant in Flat Rock, Mich. New Fusion models begin arriving at dealers nationwide this fall. Press releases, videos, photos and other material related to Ford’s electrified vehicles can be found here. The story behind the new Fusion For more on the new Ford Fusion, check out http://FordFusionStory.com, a special mobile site featuring articles, videos and graphics that are easily shareable directly from a smartphone, tablet or computer browser to Facebook, Twitter, Google+ and blogs.

Ford’s New Li-Ion Batteries Reduce Use of Rare Earth Metals, Enable Superior Fuel Economy for Fusion, C-MAX Hybrids New projected 47-mpg Ford Fusion Hybrid and EPA-certified 47-mpg C-MAX Hybrid feature lighter, more efficient, more powerful lithium-ion batteries that are expected to reduce Ford’s use of expensive, rare earth metals by up to 500,000 pounds annually Dysprosium, the most expensive rare earth metal used in Ford vehicles, is reduced by approximately 50 percent in new Fusion and C-MAX hybrids’ electric machines These rare earth metal reductions helped Ford cut the cost of its third-generation hybrid technology by 30 percent, adding to the overall value of the new C-MAX Hybrid – America’s most affordable hybrid utility vehicle starting at $25,995 – and Fusion Hybrid Ford C-Max Hybrid Forum – Ford’s third-generation hybrid system, which replaces nickel-metal-hydride batteries with new lighter, more efficient lithium-ion batteries, could reduce the company’s use of expensive, less-abundant rare earth metals by up to 500,000 pounds a year. This reduction of rare earth metals is important for both financial and physical reasons. First, the cost is reduced by 30 percent when compared to previous-generation hybrid batteries. Also, lithium-ion batteries are 50 percent lighter and 25 to 30 percent smaller. The result: Better fuel efficiency in Ford’s new electric vehicle offerings, including a projected 47 mpg for Fusion Hybrid and an EPA-certified 47 mpg for C-MAX Hybrid. “We’re continually looking to find ways to provide greater fuel efficiency as well as cost savings to customers of our hybrid vehicles, and the reduction of rare earth metals is a key part of this strategy,” said Chuck Gray, chief engineer, Global Core Engineering, Hybrid and Electric Vehicles.“The third-generation hybrid technology we are now using builds on our 20 years of electric vehicle innovations.” Among the rare earth metals used in nickel-metal-hydride batteries are neodymium, cerium, lanthanum and praseodymium, none of which are used in the new lithium-ion batteries. Additionally, Ford has reduced its use of dysprosium by approximately 50 percent in magnets employed in the hybrid system’s electric machines. Dysprosium is the most expensive rare earth metal used in Ford vehicles. This reduction is the result of a new diffusion process that is used in the magnet manufacturing process. The overall reduction of rare earth metals in the lithium-ion batteries and electric machines lowers vehicle costs, which is key as Ford triples production of its electric vehicles by 2013, ultimately translating to more affordable, fuel-efficient vehicle choices for customers. Rare earth metals are a set of 17 atomic elements in the periodic table. While some are indeed rare, others are plentiful within specific regions in the earth’s crust. These metals are used in many consumer products including mobile phones, LED televisions, computer screens and hybrid vehicle batteries. Maximum power of choice The 2013 Ford Fusion Hybrid is projected to deliver best-in-class 47 mpg on the highway, making it America’s most fuel-efficient sedan. The new Fusion will also give customers the power to choose across three powertrain options – gasoline, hybrid and plug-in hybrid. Ford’s all-new C-MAX Hybrid, in showrooms this fall, is EPA-certified at 47 mpg on the highway, 47 mpg in the city and 47 mpg combined, making it America’s most fuel-efficient hybrid utility vehicle. C-MAX Energi, launching later this fall, is projected to deliver 95 MPGe. Press releases, videos, photos and other material related to Ford’s electrified vehicles can be found here.