While I tend to think that many of the manufacturers fudge the MPG number just a tad. I would expect them to use the low end figure most of the time to be safe. If they can't consistently get that number then they just didn't build it right. It's up to them to reach that goal they set, and if they can't they shouldn't be trying to fudge the number.
Consumer Reports said that Ford has been making some eye-opening claims about the fuel economy of the redesigned 2013 Fusion Hybrid sedan and new C-Max Hybrid wagon: "47 city/47 highway/47 combined mpg." After running both vehicles through Consumer Reports real-world tests, CR’s engineers have gotten very good results. But they are far below Ford's ambitious triple-47 figures.
In Consumer Reports tests, the Fusion Hybrid delivered 39 mpg overall and 35 and 41 in city and highway conditions, respectively. For the C-Max Hybrid, we got 37 mpg overall, with 35 and 38 for city and highway. These two vehicles have the largest discrepancy between our overall-mpg results and the estimates published by the EPA that we've seen among any current models
EPA fuel-economy estimates are the result of testing on a dynamometer. It's worth noting that automakers mostly self-certify their cars. Then, the EPA spot-checks about 15 percent of them with its own tests in a lab. We have reported our fuel-economy results to the EPA.
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