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Recharge Wrap-up: Tesla details factory expansion; Ford and SunPower raise money for Sierra Club

Tesla has revealed the details of the upgrade of its Fremont, CA factory. One major change is the addition of a dedicated production space for the dual-motor P85D version of the Model S. Robots will be doing the battery installation on the Model S to save some time, and new export docks allow Tesla to get the cars out the door and on the way to their new owners more quickly. The new robots that move the cars around the factory have been named after X-Men characters, which makes our inner geeks smile. Check out the factory upgrade in the time-lapse video below and read more at Teslarati or at the Tesla Motors Blog. A program in Beijing for privileged registrations for EVs hasn't had much success. Of the 1,424 lottery winners, only about 30 percent went on to register an electric car despite a two-month extension of the deadline to do so. Buyers are likely discouraged by the lack of charging infrastructure, which the city hopes to ameliorate with the addition of 1,000 new charging stations by the end of the year, and by requiring new and renovated developments to set aside parking specifically for EV charging. Read more at Green Car Reports. The UC Davis Institute of Transportation Studies suggests that laws designed to protect dealers and consumers are stymieing the adoption of EVs. Laws like the ones certain states have in place that block or otherwise restrict Tesla's direct-to-consumer business model are not helpful for companies that want to introduce new products to the market. They prevent companies from passing on savings to customers for whom they would likely make the difference in a purchasing decision. One possible solution would be to allow exemptions to certain selling restrictions for a certain number of vehicles sold. "This could give automakers the degree of control needed to work out kinks with early customers, develop scalable processes for supporting PEVs, and ensure that effective dealer performance standards are in place before handing the reins over to wholly independent retailers," according to UC Davis ITS. Read more at the UC Davis website. Volkswagen says its environmental program, called "Think Blue. Factory," is meeting the automaker's own sustainability targets. The main purpose of the program is to move toward eco-friendlier carmaking at each of its plants worldwide.

2016 Chevy Malibu Hybrid, now with 48 mpg city

The 2016 Chevrolet Malibu is already one of the stars of the 2015 New York Auto Show thanks to a huge improvement in styling, lighter weight and new suite of tech. Now, Chevy is shifting the focus to the available hybrid model and detailing some more of its impressive figures. The 2016 Malibu Hybrid's powertrain consists of a 1.8-liter four-cylinder and a two-motor hybrid system with a 1.5-kilowatt hour lithium ion battery. Chevy's engineers are aiming for EPA fuel economy ratings of 48 miles per gallon city, 45 mpg highway and 47 mpg combined. The setup puts out a total of 182 horsepower, and it can accelerate the sedan to 60 miles per hour in a claimed 7.8 seconds. Also, speeds of up to 55 miles per hour can even be reached under fully electric power. Some of this efficient tech is shared with the latest Volt, including the regenerative braking. For reference, the 2015 Ford Fusion Hybrid carries an EPA rating of 44 mpg city, 41 mpg highway and 42 mpg combined, and its hybrid system puts out a total of 188 hp. There is a wait ahead for buyers looking to park the 2016 Malibu Hybrid in their garage, though. While the standard model should be on sale before the end of the year, the hybrid doesn't arrive in showrooms until the spring of 2016. Malibu Hybrid Estimated to Reach 48 MPG in City Driving New sedan projected to offer segment unsurpassed 47 MPG combined 2015-04-01 NEW YORK –The 2016 Chevrolet Malibu Hybrid, which uses technology from the Chevrolet Volt, will offer a General Motors-estimated 48 mpg city, 45 mpg highway – and 47 mpg combined, unsurpassed in the segment, GM President Dan Ammann announced today. Ammann made the announcement at an International Motoring Press Association breakfast before the 2016 Malibu was to be unveiled at the New York International Auto Show. "Fuel efficiency is important to our customers, especially in the midsize segment and with an estimated 48 mpg city rating, the Malibu Hybrid delivers," Ammann said. An all-new direct-injection 1.8L 4-cylinder engine mated to a two-motor drive unit slightly modified from the 2016 Chevrolet Volt drive unit powers the Malibu Hybrid. The drive unit provides additional power to assist the engine during acceleration, for 182 horsepower (136 kW) of total system power. An 80-cell, 1.5 kWh lithium-ion battery pack provides electric power to the Hybrid system. The advanced lithium-ion based chemistry can power the Malibu hybrid at up to 55 miles per hour on electricity alone.

Ford investing $500M in engine plant for 2.7L EcoBoost production

Ohio is a hot area for Ford at the moment with the announcement just a few weeks ago that production of the next-generation F-650/F-750 medium-duty trucks would move from Mexico to the Ohio Assembly Plant in Avon Lake, Ohio. Now, Ford is investing $500 million to hire 300 workers at its Lima Engine Plant in Lima, Ohio, to add production of the twin-turbo 2.7-liter EcoBoost V6 for the 2015 F-150.
The latest investment will be used to add a new flexible engine assembly system and renovate 700,000 square feet of the plant for machining and assembly areas. The Lima factory already builds Ford's 3.5-liter and 3.7-liter Duratec V6 engines. The plant opened in 1957, and it's on track to build its 40 millionth engine later this year.
Ford claims that the 2.7-liter EcoBoost will offer V8 performance with better efficiency in the F-150. It comes standard with intelligent stop/start that doesn't activate when the truck is towing or in four-wheel drive, and it's made from a combination of compacted graphite iron and aluminum for low weight and high strength. The company says that V6 engines have already proven popular in the F-150 with 57 percent of trucks in 2014 being equipped with either the naturally aspirated 3.7-liter or turbocharged 3.5-liter EcoBoost engines.