Rapidly-rising oil demand and associated greenhouse gas (GHG) emissions from road vehicles in China, passenger cars in particular, have attracted worldwide attention. As most studies to date were focused on the vehicle operation stage, the present study attempts to evaluate the energy demand and GHG emissions during the vehicle production process, which usually consists of two major stages-material production and vehicle assembly. Energy demand and GHG emissions in the material production stage are estimated using the following data: the mass of the vehicle, the distribution of material used by mass, and energy demand and GHG emissions associated with the production of each material. Energy demand in the vehicle assembly stage is estimated as a linear function of the vehicle mass, while the associated GHG emission is estimated according to the primary energy sources. It is concluded that the primary energy demand, petroleum demand and GHG emissions during the production of a medium-sized passenger car in China are 69,108 MJ, 14,545 MJ and 6575 kg carbon dioxide equivalent (CO2-eq). Primary energy demand, petroleum demand and GHG emissions in China's passenger car fleets in 2005 would be increased by 22%, 5% and 30%, respectively, if the vehicle production stage were included. (C) 2009 Elsevier Ltd. All rights reserved.