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A car first .. a badge second

August 2004

By John Simister

The Hyundai Automotive Group is currently the world's seventh-biggest carmaker in terms of units produced, but it wants to be number five by 2010, by which time this agglomeration of Hyundai and Kia is predicting an annual output of 5.7 million cars across worldwide factories, with 3.8 million for Hyundai and 1.9 million for Kia. However, if the Korean carmaker is to be number five, it must overtake two of the three combines that lie immediately ahead: PSA Peugeot Citroën, DaimlerChrysler and the Volkswagen Group, but how can it do that, asks John Simister.

Hyundai will not be by selling massively more cars in Korea, because along with Kia (It acquired Kia in 1998) it already has 70 per cent of a near-saturated domestic market. Therefore, emerging markets are the key, as they are for rival carmakers, and Hyundai already has a major manufacturing presence in China and India. A new Kia factory in Slovakia is under construction, and there is to be a concerted push in European markets to raise share above the current 2.7 per cent across the two brands. That 5.7 million represents a doubling of the corporation's 2002 output. It is an almost frightening thought.

The Getz supermini, known as Click in some markets
Getz

It was the strength in China, where the Sonata and Elantra are two of the best-selling cars and Hyundai is a major player in the truck sector, that appealed to DC when it acquired its 10.5 per cent stake in Hyundai Motor for €324mn ($400mn) in 2000 after the car division was hived off from the rest of Hyundai following Korea's 1998 economic meltdown. DC is now selling that stake as it restructures its global operations, possibly to compensate for losses incurred with Mitsubishi whose former DC shareholding has now passed to other Mitsubishi companies, but Hyundai – which already has a high stock level and is very profitable – will not be buying it back.

Hyundai's other links with DC are not affected, however. There are four main joint ventures: purchasing of parts, Chrysler/Dodge-badged Hyundais in markets such as Mexico, a new four-cylinder engine range to be used in several Chrysler and Mitsubishi products, and another new engine currently under wraps. The four-cylinder Theta unit, to be launched first in the next Sonata due this autumn, spans capacities from 1.8 to 2.4 litres, and is a dohc 16-valve unit with an aluminium block and head and two sump-mounted, chain-driven balancer shafts. Later versions of this 'global engine' will be made at Chrysler's Auburn Hills factory in the US, adding variable exhaust-cam timing to that for the inlet cam, and there will be turbocharged derivatives from 2007.

In China the Sonata and Elantra (right) are two of the best selling cars

Hyundai's global ambitions will call for much streamlining of its present product portfolio, bringing the current tally of 21 platforms down to somewhere between eight and 14 by 2008. Examples are the next Hyundai Trajet and Kia Sedona MPVs, to be built on a common base. And from a European perspective, especially, Hyundai's range lacks cohesion and progression even more than Kia's does. There is the Getz supermini (known as Click in some markets), which is understandable enough, but then we have the Accent, Elantra and Sonata all sitting in between established market segments with nothing in the crucial Golf/Focus class.

This, though, is about to change. "We will have a real C-segment car for 2006," says Werner Frey, vice president of Hyundai Motor Europe which has just opened a €50mn ($62mn) research and development centre at Russelsheim, Germany, "and we shall also increase the number of variants in each model range," he adds.

Therefore we can expect, for example, compact-MPV and estate car spin-offs, but while Hyundai and Kia will make their cars more 'European' in style there will be no specific European range along Toyota lines. They will be global cars, some suited to particular markets better than others: the Euro-look Getz, for example, sells poorly in its home market where the Sonata reigns.

There is also the matter of differentiating between the products of Hyundai and Kia, which in Hyundai's case will first bear fruit in that C-segment car. The problem is similar to that faced by PSA with Peugeots and Citroëns, and by the VW Group stable. "There will be some overlap but also some reserved segments," explains Frey, "and we will differentiate with minor things. There will be a clear design language, a family look, brand specific interior materials. Hyundai will be more refined, higher in quality. Kia will be affordable, dynamic and sporty."

Back in Korea, the man overseeing the positioning of Hyundai and Kia is Young-II Kim, a former designer who in previous lives helped shape the SsangYong Musso SUV and the Panther Solo (Panther was latterly owned by another Kim and parts of the cars came from Korea). What, then, are the characteristics of each make?

"We have a short history," the younger Kim reminds us, "and frankly we do not have a characteristic. What we do have is an emotional feeling," he says. That 'e' word is a favourite among the world's car designers and marketeers, but it is hardly a commodity to be picked off a shelf. Kim elaborates on the emotional aspect: "Look at the front of the Sonata, at the shape of the bonnet and fender, or at the flanks of the Santa Fe off-roader. They are sculptural, muscular. That's our look."

What Hyundai cars lack so far is a consistent 'face' – currently some have vertical bars like teeth, others (such as the Santa Fe and the European-styled Getz) have neater air-slots, but the designers are working on that. The idea is to move Hyundai a little upmarket, to make it a 'smart buy' instead of a cheap car much as Skoda has done. Kia, meanwhile, will become a 'sportier' brand, and to this end a new sports car is on the agenda. Its last one was a remake of the 1989 Lotus Elan, and was not a great success. That said, Hyundai is re-entering the World Rally Championship from late 2006. Clearly there remains some brand-identity confusion.

Hyundai has its research and development centres in Germany, Japan and the US, but the hub is the recently-opened Namyang centre near Seoul whose life-size, panoramic viewing screen for virtual reality moving presentations (complete with real-world backgrounds) of design proposals is very impressive. Namyang is far away from the production bases in the south of the country, but it is easier to attract a high calibre of staff if they can live near Seoul.

There are plenty of projects on the go at Namyang. A Getz has been recreated in aluminium, and there is a batch of 50 petrol-electric hybrids under test. The powertrain is devised along the lines of Honda's Civic IMA, using a 12kW motor to assist the 1.4-litre gasoline engine and achieve a fuel efficiency of up to 54 per cent better than that of a 1.5 litre gasoline-only Getz. It might enter production if the trials go well.

Entering the 'green' race

Driving the hybrid at Namyang, for the most part it behaved like a conventional gasoline-engined example whose only obvious sign of unconventionality, apart from a CVT transmisssion, was a gauge to show the charge remaining in the boot-mounted battery pack. Is this the smallest current production-feasible hybrid?

Hyundai is also well placed in the fuel cell race, with a Santa Fe FCV having won four medals at last September's Michelin Challenge Bibendum in California for alternative fuel vehicles. The Santa Fe FCV uses fuel cell stacks from UTC Power, as does the next stage in the programme, a fuel cell version of the new Tucson compact SUV complete with lightweight aluminium panels. This Tucson is claimed to cover about 109km on 4.5 litres of compressed hydrogen, and its creators say they have solved the fuel cell problem of freezing in cold weather. Hyundai plans to have fuel cell production cars by 2010, and meanwhile a fleet of fuel cell Tucsons is about to go on trial.

Hyundai remains wedded to the idea of a battery pack to give instant power while the fuel cell works up to its output, but unlike the Santa Fe FCV, which had an underfloor fuel-cell stack, the Tucson has its stack under the hood. The electric motor is by Enova, the 152 volt Lithium-ion polymer battery is a joint venture between Hyundai and LG. Peak motor output is 107ps (80kW), for a maximum speed of 150km/h.

Another Hyundai research project, still in its early stages, is the CAI (Controlled Auto Ignition) petrol engine, which has no spark plugs but uses the heat of back-flowing exhaust gases to ignite the petrol-air mixture. "The advantage is clean, homogeneous combustion; the challenge is to control it," says head of research Dr J C Park.

Hyundai is clearly determined to reach its fifth-place goal by 2010, and cement Korea's position as a world player. Two of the rivals will have to give ground for this to happen. Who will they be?