Powertrain Strategies of the Japanese OEMs2012 Edition

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CONTENTS

INTRODUCTION .......................................................................................................... 6

TARGETS ................................................................................................................... 7

ENGINES ..................................................................................................................... 10

TOYOTA MOTOR CORP. ........................................................................................ 10

Hybrids to play bigger role... .................................................................................... 12

Operations .............................................................................................................. 13

DAIHATSU MOTOR CO.......................................................................................... 18

FUJI HEAVY INDUSTRIES, LTD. ........................................................................... 20

Fuji Heavy’s ‘Fa’ Engine... ...................................................................................... 21

HONDA MOTOR CO. .............................................................................................. 21

IHS Automotive Forecasts....................................................................................... 23

Operations .............................................................................................................. 23

HYUNDAI MOTOR CO. & KIA MOTORS CORP. .................................................. 25

R series specifications: ............................................................................................. 26

U series specifications: ............................................................................................. 27

Overseas Operations ................................................................................................ 27

ISUZU MOTORS, LTD. ............................................................................................ 31

MAZDA MOTOR CORP. ......................................................................................... 31

Rotary Revival ........................................................................................................ 33

Operations .............................................................................................................. 33

MITSUBISHI MOTORS CORP. ................................................................................ 36

Operations .............................................................................................................. 36

NISSAN MOTOR CO. .............................................................................................. 39

IHS Automotive Forecast... ..................................................................................... 39

Operations .............................................................................................................. 40

SUZUKI MOTOR CORP. ......................................................................................... 44

Operations .............................................................................................................. 44

JAPANESE TRUCKMAKERS .................................................................................. 46

TRANSMISSIONS ........................................................................................................ 47

TOYOTA ................................................................................................................... 47

AISIN AW CO. .......................................................................................................... 48

AISIN AI Co. ............................................................................................................. 53

TOYOTA MOTOR HOKKAIDO, INC. .................................................................... 55

DAIHATSU ............................................................................................................... 56

HONDA .................................................................................................................... 57

Operations .............................................................................................................. 58

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HYUNDAI POWERTECH CO. ................................................................................ 59

HYUNDAI WIA CORP............................................................................................. 61

JATCO, LTD. ............................................................................................................ 62

The Market ............................................................................................................. 63

Operations .............................................................................................................. 63

MANUAL TRANSMISSIONS ...................................................................................... 65

AICHI MACHINE INDUSTRY CO. ..................................................................... 65

HYBRIDS & EVS .......................................................................................................... 73

TOYOTA ................................................................................................................... 73

EVs ......................................................................................................................... 74

HONDA .................................................................................................................... 79

HYUNDAI & KIA ..................................................................................................... 80

MAZDA .................................................................................................................... 82

MITSUBISHI ............................................................................................................. 82

NISSAN ..................................................................................................................... 84

Leaf Leads EV Way ................................................................................................ 84

SUZUKI .................................................................................................................... 87

HINO & JAPANESE TRUCKMAKERS ................................................................... 87

LIST OF TABLES AND FIGURES

Table 1: 2015 Fuel Economy Targets in Japan & South Korea (Source: JAMA & Asian Clean Fuels Association) .................................................................................................. 8Table 2: Japanese Government Future Vehicle Penetration Targets (Source: Japan’s Ministry of Economy, Trade & Industry) .......................................................................... 8Table 3: Hybrid/EV Production Outside Japan & South Korea (Source: Companies) ......... 9Table 4: Toyota Engine Lineup (Source: Companies) ...................................................... 10Table 5: Toyota Industries Engine Lineup ....................................................................... 13Table 6: Toyota’s 2011 & 2010 North American Engine Production Results (in units) (Source: Toyota Motor Engineering & Manufacturing North America Inc.) ..................... 18Table 7: Daihatsu Engine Lineup .................................................................................... 19Table 8: Engines Produced for Toyota in Fiscal 2011 (Source: Daihatsu) ......................... 19Table 9: Honda Engine Lineup (Source: IHS Automotive, Honda) .................................. 25Table 10: Hyundai & Kia Engine Lineup ........................................................................ 28Table 11: Isuzu Engine Lineup ....................................................................................... 31Table 12: Mazda Engine Lineup ..................................................................................... 34Table 13: Mitsubishi Engine Lineup ................................................................................ 37Table 14: Nissan Engine Lineup ..................................................................................... 42Table 15: Suzuki Engine Lineup ..................................................................................... 45Table 16: Toyota’s Main CVT & Automatic Transmission Series(a) Source: IHS Automotive, companies .................................................................................................. 47

Powertrian Strategies of the Japanese OEMs

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Table 17: Aisin AW Transmission Lineup ....................................................................... 50Table 18: Aisin AW OEM Customers ............................................................................. 52Table 19: Aisin AI Transmission Lineup ......................................................................... 54Table 20: Honda’s Transmission Lineup (Source: IHS Automotive) ................................. 59Table 21: Hyundai Powertech Transmission Lineup ........................................................ 60Table 22: CVT Installation by Automaker & Model ........................................................ 65Table 23: JATCO Automatic Transmission Lineup ......................................................... 70Table 24: Aichi Machine Manual Transmission Lineup ................................................... 71Table 25: Fiscal 2010 & 2011 Hybrid & EV Sales (in units) Source: WardsAuto ............... 76Table 26: Energy Efficiency by Vehicle Type (Source: Toyota) ........................................ 79Table 27: Lithium Energy Japan’s plant investment history (Source: Lithium Energy Japan)

...................................................................................................................................... 83Table 28: Nissan Battery Plant Investment (Source: Companies) ...................................... 85Table 29: Global Engine and Transmission Assembly plants of Japanese OEMs, with 2011 output ............................................................................................................................ 89Figure 1: Honda’s 1.8L gasoline engine ........................................................................... 22Figure 2: Honda’s 3.5L V6 gasoline engine ..................................................................... 22Figure 3: Honda’s 1.6L diesel engine ............................................................................... 23Figure 4: Hyundai-Kia’s1.6L Gamma GDI Turbo engine ................................................ 31Figure 5: Isuzu’s 4JB1 diesel engine ................................................................................ 31Figure 6: Mazda’s ‘4-2-1’ residual gas reduction exhaust system ...................................... 35Figure 7: Schematic showing fuel economy improvement of Mazda’s Skyactiv-D diesel engine ............................................................................................................................ 35Figure 8: Schematic showing fuel economy improvement of Mazda’s Skyactiv-G diesel engine ............................................................................................................................ 36Figure 9: Mitsubishi’s 2.0L Gasoline engine .................................................................... 38Figure 10: Mitsubishi’s 660cc Gasoline engine ................................................................ 38Figure 11: Suzuki Powertrain India Diesel based on Fiat Technology .............................. 46Figure 12: Daihatsu's CVT for 660cc minicars with schematic ......................................... 57Figure 13: Honda’s new CVT for mid-sized cars, in the new N Box minivan .................... 58Figure 14: Hyundai-Wia’s rear drive transmission ........................................................... 62Figure 15: JATCO’s CVT7, CVT8 and CVT8 hybrid transmission ................................... 64Figure 16: Toyota's FCV-R fuel cell car ........................................................................... 75Figure 17: Toyota Prius's battery pack ............................................................................. 75Figure 18: Toyota Prius c/Aqua ..................................................................................... 76Figure 19: Honda's Fit EV x 2 ......................................................................................... 80Figure 20: Hyundai Sonata Hybrid & Kia Optima Hybrid lithium battery pack and schematic of Hyundai Sonata Hybrid's powertrain ........................................................... 81Figure 21: Powertrain layout of Mitsubishi's i-MiEV electric car ...................................... 83Figure 22: Mitsubishi's i-MiEV lithium battery pack ........................................................ 84Figure 23: Nissan's front-drive hybrid system ................................................................... 85Figure 24: Nissan's new Xtronic CVT ............................................................................. 86Figure 25: Nissan's new fuel cell stack ............................................................................. 86Figure 26: Nissan Leaf battery assembly .......................................................................... 87

Powertrian Strategies of the Japanese OEMs

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