All-New 2023 Honda CR-V Hybrid Production Begins in North America

All-new Honda CR-V Hybrid with Fourth Generation Honda Hybrid System Honda engine and transmission plants in Ohio are playing a pivotal role in the launch of new CR-V Hybrid featuring a newly refined Atkinson cycle engine and Fourth Generation CR-V Hybrid hybrid system starts production in Canada, soon to be followed by plants in Indiana and Ohio, as it will account for about 50% of CR-V sales CR-V is America’s best-selling crossover of the last quarter-century

Employees from multiple Honda plants in North America today celebrated the start of mass production of the all-new 2023 Honda CR-V hybrid at Honda of Canada Mfg. (HCM), featuring a new twin-engine hybrid system produced at Honda’s Ohio Transmission Plant (TMP-O), and a newly refined Atkinson cycle engine unique to hybrid models made at Ohio’s Anna Engine Plant (AEP).

The Indiana Auto Plant (IAP) and East Liberty Auto Plant (ELP) in Ohio, which produced the previous CR-V Hybrid, will begin production of the 2023 CR-V Hybrid in the coming months. HCM is the world’s leading plant for the production of CR-V hybrids, the first time a hybrid has been built in Canada.

A key step in Honda’s electrification strategy, starting with the 2023 model year, approximately 50% of CR-V’s annual US sales will be powered by Honda’s new, more powerful, fourth-generation hybrid-electric twin-engine system.

“We know the importance CR-V hybrid will play in our overall electrification strategy, and this is a proud moment for the Honda of Canada Mfg. team as we lead the start of CR-V hybrid production worldwide,” he said. Clement D’ Souza, senior vice president of HCM.

The all-new 2023 Honda CR-V Sport and Sport Touring trims come standard with the new hybrid system featuring the more refined 2.0-litre Atkinson cycle four-cylinder engine and Honda’s new fourth-generation twin-engine hybrid-electric system, featuring a pair of electric motors now arranged side by side in a parallel shaft layout.

The new CR-V is perfect for everyday life or weekend getaways. It is longer and wider with premium proportions and a significantly wider stance, further promoting Honda’s robust design direction for light trucks with a low horizontal beltline and a long, powerful front end. Honda’s most popular SUV supports its strong new look with a more fun-to-drive personality, more confident and refined dynamics, and more torque and capability. For product details, click here.

New hybrid-electric powertrain made in Ohio All three plants that produce CR-V in North America, HCM, IAP and ELP, worked closely with the Anna Engine Plant (AEP) and the Honda Transmission Plant in Ohio (TMP-O) , who are responsible for the all-new powertrain for Honda’s latest electrified car.

With the sales plan of the new CR-V and Accord hybrid trims expected to represent approximately 50% of each model’s sales mix, and three different Honda plants in North America producing the new CR-V hybrid models, both AEP as TMP-O, the production volume for the new engine and hybrid system had to increase dramatically. For AEP, this increase included more in-house production of engine components and an increase in local sourcing of parts previously supplied from Japan. For example, AEP now produces the camshaft for the engine in-house, requiring new equipment and a greater number of processes for employees. TMP-O employees will increase the production volume of the twin engine system by 300% (from 500 to 1500 units per day) within the first two to three months.

“AEP employees have always supported the evolution of our company and we are proud to be the sole supplier of this engine to all three of our North American CR-V frame plants,” said Rick Riggle, AEP factory head . “The team has worked hard to prepare production lines for casting, machining and assembly operations. This is an important step towards electrification for our company and our employees will be ready to take on the challenge.”

The 2.0-litre Atkinson cycle four-cylinder engine built at AEP is the first Honda engine to combine high-pressure direct injection with multi-stage injection for an extremely homogeneous mixture that ensures clean combustion. To manage high exhaust temperatures, the cylinder head uses a new two-piece water jacket, new gas-cooling exhaust ports and a large-capacity cooled exhaust gas recirculation (EGR) valve to return exhaust gases from the exhaust system back into the chamber to reduce emissions.

Largest cylinder head ever: The cylinder head is the largest ever produced by AEP’s employees, requiring modifications to the cylinder head casting area. The cylinder head molding department implemented a unique sand core mold designed by the production engineering team to accommodate the new EGR valve and improve productivity for cylinder head production. New soundproofing: The engine also features a stiffer crankshaft and secondary balancer to reduce vibration and a full urethane hood, a first for Honda. Honda employees at AEP apply new lightweight fiber foam insulators, which are highly resistant to heat and vibration, directly on the engine in three different places, creating a quieter and more comfortable ride.

The fourth-generation dual-motor hybrid-electric system, made at TMP-O, has a new arrangement, switching from coaxial motors of the same size stacked on top of each other to a twin-motor system with parallel shafts with motors of different sizes which are mounted on the side. -on the side. The new system also includes new high and low speed lockup ratios for direct motor drive on the highway and in the city. Overall, the new design improves responsiveness for a sportier driving feel and provides a more relaxed driving environment at highway speeds. It also provides a higher sustained top speed, improves fuel economy and allows for towing up to 1,000 pounds.

“TMP-O employees are proud and excited to provide the next generation of components for the 2023 CR-V hybrid,” said Gerald Bruch, head of the TMP-O plant. “We are fully committed to our electrified future, and this is the first of many steps our employees will take to help Honda achieve its goals for a carbon neutral future.”

The role of the lead factory increases the local procurement of parts: TMP-O is the lead factory for the production of the new twin engine system in North America. Coupled with the increased volume production to meet Honda’s hybrid sales strategy, TMP-O employees were challenged with a greater number of parts – more than double the previous system – to be matured for mass production. The new system has more than 80 new parts sourced from local suppliers, compared to just over 20 parts with the outgoing system. Advanced production technology: Smart automation has been applied at several locations to minimize the number of machines added by TMP-O to manufacture the new system, increasing efficiency and reducing the need for additional space and investment. For example, TMP-O’s machining department worked on making functions common and minimizing the need for exclusive tools. The assembly team then worked on applying flexible automation using common robots that can quickly change the end-of-the-arm tooling when running different models. This was a unique approach to what Honda plants in Japan and China were pursuing and paid off with greater flexibility and efficiency and more efficient use of floor space at the Ohio plant. Juggling Responsibilities: While installing new equipment and processes for the fourth-generation twin-engine hybrid-electric system, TMP-O also had to continue manufacturing the third-generation twin-engine system on the same production lines to meet demand to meet record sales of current CR-V and Accord hybrid models. Key strategies included using sub-assembly lines for the new shaft to keep the main assembly line processes the same, even with different and larger parts. TMP-O employees also worked to reduce the time required for line adjustments by a month and a half, allowing the team to begin production trials earlier and continue production of the previous-generation twin-engine unit.

Honda production in North America Honda has been manufacturing cars in North America for 40 years, beginning November 1982 at the Marysville Auto Plant. Honda began manufacturing operations in North America in 1979 with motorcycle production in Marysville, Ohio.

Over the past four decades, Honda has steadily expanded its local manufacturing capacity and now employs more than 30,000 people in 18 plants with an annual production capacity of 1.86 million cars, nearly 4 million motorcycles, 500,000 electrical equipment products and 300,000 power sports products, as well as the HondaJet advanced light jet and GE Honda HF120 turbofan engines. By 2021, more than 95% of all Honda and Acura cars sold in the US were made in North America, using domestic and global parts.

In total, Honda has invested nearly $24.6 billion in its North American manufacturing capabilities, more than $3.6 billion in the past five years alone. The company partners with nearly 800 original equipment suppliers in North America with cumulative parts purchases in excess of $535 billion.

Learn more via the Honda Digital FactBook.

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1. Honda products are made with domestic and worldwide parts.

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