Updated: January 2014

TOYOTA HILUX

KEY POINTS

·  Sixth generation of the legendary Toyota Hilux

·  Europe’s best-selling pick-up

·  Fuel-efficient Euro 5 powertrains

·  142bhp 2.5 D-4D with 194g/km CO2 emissions

·  3.0-litre D-4D delivers 169bhp and 343Nm of torque – 360Nm with auto transmission

·  Tested in the world’s most extreme environments for ultimate toughness – Hilux the first car to be driven to both the Magnetic North and South Poles

·  Independent double wishbone front suspension

·  Rear differential lock standard on all 2.5-litre models

·  Three grades – Active, Icon and Invincible

·  Automatic Disconnecting Differential standard on all grades

·  Vehicle Stability Control standard on flagship Invincible grade

·  Toyota Touch 2 multimedia touchscreen system with Bluetooth and rear-view camera standard on Icon and Invincible models

·  Single Cab, Extra Cab and Double Cab body styles

·  Selectable four-wheel drive, with shift-on-the-fly facility

·  ABS and driver and front passenger airbags, air conditioning, electric windows and remote central locking standard on all versions

INTRODUCTION

Famed for its ultra-tough quality, Hilux is much more than just a workhorse. Today’s sixth generation of Toyota’s pick-up combines traditional robustness and excellent load-carrying capacity with comfort, safety and equipment features to make it a vehicle that ably bridges the divide between the work and everyday driving needs.

The Hilux package was strengthened with re-engineering of its common rail 2.5 and 3.0 D-4D turbo diesel engines to meet Euro 5 emissions standards. As a result, performance, fuel efficiency and CO2 emissions were improved. The engines work with refined manual and automatic transmissions and combine with the benefits of a strong and rigid body construction to give Hilux surefooted performance both on and off-road.

DIESEL ENGINES

3.0-litre D-4D 170

The 3.0-litre D-4D is a derivative of the engine used in the Toyota Land Cruiser. It uses second-generation common rail technology, a variable nozzle turbocharger and a swirl control system for operating efficiency. This contributes to the Hilux’s refined on-road performance, with low levels of noise, vibration and harshness. It is available in the Hilux Double Cab Invincible, with five-speed manual or automatic transmission.

The engine delivers 169bhp/126kW at 3,600rpm and has a torque output of 343Nm all the way from 1,400 to 3,400rpm. In models fitted with automatic transmission torque is boosted by 17Nm to give a maximum 360Nm between 1,400 and 3,200rpm. Top speed is 106mph (109mph auto).

The engine benefits from a series of technical adjustments to meet Euro 5 emissions standards, including a diesel particulate filter (DPF), next-generation piezo-injectors, a re-profiled combustion chamber and a compression ratio reduced from 17.9:1 to 15.0:1. Changes were also been made to the transmissions, with a revised differential gear ratio on the automatic unit and a reduction in the fifth gear ratio in the manual gearbox, supporting better fuel efficiency.

Thanks to the changes introduced, combined cycle fuel consumption with five-speed manual transmission improved from 34 to 36.7mpg, while with the five-speed automatic, the improvement was from 31.7 to 32.8mpg. Meanwhile carbon emissions were pegged back from 219 to 203g/km for the manual and from 236 to 227g/km for the automatic.

The engine has an iron-alloy block with an aluminium alloy cylinder head, with four valves per cylinder. Two separate, differently-shaped input ports help promote a good fuel mixture and swirl. The crankshaft has five journals and eight balancing weights, with two counter-rotating balancer shafts to help reduce vibration. The design and position of the engine mounts have been carefully calculated to further reduce vibration and improve ride comfort.

The second-generation common rail system develops a high injection pressure and allows the use of injector nozzles with smaller diameter holes. This creates a more homogenous air-fuel mixture, improving combustion efficiency and thus delivering better performance with lower emissions and fuel consumption.

Across a wide range of engine speeds (800 to 3,000rpm), the common rail system performs a double pilot injection per cycle, prior to the main injection, to distribute the appropriate amount of fuel. This reduces both combustion noise and engine vibration.

A variable vane turbocharger is a key element in the engine’s high power and torque output, balancing exhaust back pressure and boost pressure according to the precise demands of the engine. The variable nozzle mechanism is activated by an electric DC motor, instead of the usual step motor, giving sharper turbocharger response, particularly at lower speeds, and higher precision vane activation.

The engine also uses a swirl control system. Each cylinder is fed an air and exhaust gas mixture through two different, independent ducts. The swirl control system operates butterfly valves that can close off either of these ducts according to engine speed and load, so increasing the mixture’s swirl rate.

The engine’s emissions performance is supported by the use of an Exhaust Gas Recirculation (EGR) cooler, with integrated bypass and a switching valve to optimise the EGR gas temperature. At low engine speeds this improves the fuel-air mixture, further increasing the torque available and reducing emissions.

2.5-litre D-4D

Similar revisions, including the fitting of DPF, were made to the 2.5-litre D-4D engine, which also meets Euro 5 emissions requirements. As a result of the adjustments to the engine, CO2 emissions for the 2.5 D-4D (Double Cab) were cut by more than 10 per cent to 194g/km, and combined fuel consumption was improved by more than 10 per cent to 38.7mpg (all body styles).

Well-established as the core power unit for the Hilux range, it produces 142bhp/106kW at 3,400rpm, and a maximum 343Nm of torque, giving an excellent balance of flexible driving performance and low fuel consumption.

The engine benefits from a variable nozzle vane-type turbocharger, activated by a DC motor, and fuel injectors that operate with greater precision, improving throttle response and performance.

Engine performance is supported by an intercooler, at low speed torque is boosted by the inclusion of a two-stage swirl control valve in the intake manifold, similar to that used on the 3.0 D-4D, which improves the swirl rate at low intake pressures.

Just as with the 3.0-litre engine, better emissions performance has been achieved by fitting an EGR cooler.

The 2.5-litre D-4D engine is matched to a five-speed manual transmission, and is offered in all three Hilux body styles.

TRANSMISSIONS

The Hilux range uses a five-speed manual transmission, with a five-speed automatic gearbox available as an option with the 3.0-litre D-4D engine.

A full range of drive options is offered, including shift-on-the-fly changes between two and four-wheel drive and an Automatic Disconnecting Differential (ADD). ADD automatically engages or disengages the front differential according to the selected drive mode, even when the vehicle is moving, helping improve fuel efficiency and cutting noise levels.

Hilux has a part-time four-wheel drive system that operates in rear, two-wheel drive in normal conditions, with all-wheel drive engaged on low-grip surfaces and when going off-road.

Five-speed automatic

The five-speed automatic gearbox uses Artificial Intelligence (AI), adapting the gear shift pattern to suit individual driving style and road conditions. This Toyota-developed system automatically detects and reacts to up and downhill gradients, reducing the number of gearshifts and enabling good use of engine braking.

Five-speed manual

The five-speed manual gearbox gives refined driving performance on and off-road, with smooth changes and excellent fuel consumption. The transmission is tuned for off-road climbs and descents, where it gives excellent control over engine braking and vehicle speed. The Hilux is especially smooth at tick-over, which makes for easy driving in first gear at engine idle, with no need to keep your foot on the accelerator; it is almost impossible to stall the vehicle.

OFF-ROAD PERFORMANCE

Today’s Toyota Hilux has to satisfy a wide range of demands, from family leisure vehicle to off-road workhorse. While the vehicle has developed to meet the different needs of customers, it retains the rugged qualities that have made it a legend around the world, not least its remarkable off-road abilities.

In May 2007, Hilux became the first car to be driven across the Arctic ice to the Magnetic North Pole, a feat achieved by Jeremy Clarkson and James May of the BBC’s Top Gear television programme.

In January 2009 Hilux achieved the double, reaching the South Pole as a support vehicle for the Amundsen Omega3 Ski Race. With three vehicles covering more than 3,000 miles each in temperatures as low as -40C Hilux proved to be a faster, more reliable and fuel efficient means of transport than snowcats. The vehicles used for both challenges were specially adapted for the purpose by Arctic Trucks of Reykjavik, in Iceland.

Hilux is built on a stiff ladder frame chassis. The TOP (Toyota Outstanding Performance) platform, has strengthened cross-member joints that increase frame rigidity, adding to the vehicle’s famous robustness. This not only contributes to the vehicle’s off-road capability and durability, proven in some of the world’s harshest environments, it also offers better NVH insulation between the cabin and the chassis.

The independent front suspension and rear leaf springs are designed to cope with the toughest conditions, while maintaining a comfortable ride and direction control when travelling on-road.

But it is the Hilux’s engines – the 3.0-litre D-4D and 2.5-litre D-4D – that most clearly demonstrate what this machine can achieve off-road. With their high torque output across a wide engine speed range, they allow the driver to enjoy top performance at any speed and on any terrain.

All Hilux models are fitted with 297mm diameter ventilated front disc brakes and 295mm drums, apart from the Invincible with Vehicle Stability Control, which has 319mm ventilated front discs.

Thanks to the quality of the five-speed manual transmission, steep descents on rough ground can be negotiated safely and securely with the engine on tick-over in first gear. The high torque output means the Hilux can equally make steep ascents on engine idle, too.

Ground clearance for all models is generous at 212mm and approach and departure angles of up to 30 and 22 degrees respectively enable steep inclines to be tackled. The ramp angle is 25 degrees. From off-road to in-water, performance is strong, with a wading depth of up to 700mm.

The current generation Hilux Double Cab has 25 per cent more load space than the previous model. Maximum braked towing capacity is 2,800kg for both engines – an increase from the model’s original 2,500kg maximum.

Superior traction control

Hilux’s 4WD system allows the driver to shift from four to two-wheel drive (H4 to H2) with no speed restriction and from two to four-wheel drive at speeds up to 50mph (80km/h). In tough off-road conditions, the synchronised shift mechanism enables shifts from H4 to L4 (or vice-versa) to be made while on the move, at speeds up to 5mph (8km/h).

Toyota’s Automatic Disconnecting Differential (ADD) is fitted as standard to all models. This automatically engages or disengages the front axle drivetrain with the shift from four to two-wheel drive, contributing to fuel efficiency and lower noise levels in 2WD mode.

A rear diff lock is standard on all models with the 2.5 D-4D engine, further improving off-road capabilities. It is activated manually, via a button on the dashboard.

SUSPENSION

The Hilux’s suspension is designed for strong handling performance on and off-road, with a comfortable ride and straight-line stability. The independent front suspension features double wishbones and coil springs for good bump absorption while maintaining steering feel and ride comfort.

The front suspension geometry is designed for straight line stability, with increased caster angle and a smaller kingpin offset for good braking stability. To improve the roll feeling and reduce body roll, shock absorber damping has been increased and the anti-roll bar connected to the upper suspension arm with ball joints, giving greater rigidity. The coil springs are made of stiffer, high-tensile steel to reduce unsprung weight.

A conventional but precise leaf-spring system is used at the rear, avoiding any intrusion in the cargo deck and providing a flat ride, particularly when the Hilux is running unladen or with a light load.

Detail elements, such as double-row, roller-type rear axle bearings, a responsive valve structure on the front shocks and strategically positioned bushes help produce a quiet, refined ride that is more like that of a passenger car than a rugged utility vehicle, even at speed.

The power-assisted rack-and-pinion steering has a larger steering frame structure for improved torsional stiffness, which means Hilux is stable and agile on-road, while giving strength and good bump absorption off-road. The vehicle has a compact 6.2m turning radius.

STYLED FOR A CHANGING MARKET

The 2014 Hilux carries forward an earlier comprehensive re-style that introduced a new bonnet, radiator grille, headlamps and bumper, plus new wheel designs and new side bars and steps for the top-of-the-range Hilux Invincible.

At the rear the lamp units have clear indicator lenses and a silver trim band. The high-mounted stop light also has a clear lens. All models, including Active, have a rear step bumper, while the Invincible further adds side steps in addition to its chrome side bars for easy access to the cabin.

The interior’s upper dashboard design and horizontal instrument cluster emphasise the breadth and roominess of the cabin. For 2014 the cabin plastics and the cloth upholstery were rendered darker in tone to give a smarter appearance.

The dash lay-out incorporates the Toyota Touch 2 multimedia unit with a full colour 6.1-inch touchscreen (details below)

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Hilux is easily identified by its trapezoid front grille with a grey metallic plate bar bonnet air scoop and, on Icon and Invincible models, round front fog lamps set into the outer corners of the bumper. Fifteeen and 17-inch alloy wheels are featured on the Icon and Invincible models respectively.

The headlamp units have clear lenses for the front turn indicator lights and the upper and lower grilles have a large honeycomb mesh design.

The current generation Hilux, launched in 2005, was designed to be “one size up” from the previous model, giving both more road presence and more interior space, in keeping with customer preference. The load deck also grew in size, giving 25 per cent greater capacity. Load lengths are 2,340m for the Single Cab, 1,830mm for the Extra Cab and 1,545mm for the Double Cab.