Toyota HiLux BEV
The BEV model is an integral part of the all-new ninth generation Hilux range, giving customers the option to enjoy the model's exceptional Quality, Durability and Reliability with the critical benefit of zero tailpipe emissions. It is an authentic Hilux, powered by electricity.
It will enter a new and developing market for electric pick-ups, appealing primarily to businesses seeking to decarbonise their vehicle fleet and comply with increasingly stringent legislation while still enjoying rugged, reliable performance. Toyota Hilux BEV will be particularly suited to single-location operations, such as forestry, industrial complexes and infrastructure sites such as airports and ferry terminals. The model will also attract individual buyers - both small businesses and private buyers focused on leisure use.
Accommodating the new powertrain is not at the cost of Hilux's ability to operate in the most challenging environments, nor the space inside the cabin and load bay. Off-road performance maintains the model's reputation as a trusted partner that can take challenging terrain in its stride.
This is Toyota's first use of BEV technology in a body-on-frame vehicle, a construction type that has been key to Hilux's built-in strength and capabilities from the start. Moreover, this has been achieved without diluting the pick-up's off-road prowess - for example, the exceptional 700 mm wading depth is equal to the capability of Hilux Hybrid 48V and ICE models.
There is a further breakthrough with the first application of Toyota's Multi-Terrain Select (MTS) System in a BEV, which automatically adapts vehicle performance to suit different off-road conditions, from rock, sand and mud to dirt and - another BEV first - bumpy mogul surfaces.
The powertrain comprises front and rear eAxles that combine an electric transaxle and inverter in a single compact and lightweight unit. They are engineered for optimum efficiency with detailed measures to reduce internal losses and energy lost as heat. To accommodate the eAxles, a new-design front crossmember and an additional rear crossmember have been added to the Hilux's frame. The eAxles themselves are reinforced and fitted with undercovers to ensure they can withstand harsh off-road conditions. This strengthens the BEV's profile as a capable vehicle for work duties, true to Hilux's famous Quality, Durability and Reliability.
The inverter uses silicon carbide (SiC) semiconductors which can handle high voltages and are more efficient (up to 40%) than the traditional silicon type. The front eAxle produces 80 kW and 205 Nm of torque and the rear unit 128 kW 268 Nm, ensuring strong traction and control, particularly in demanding off-road conditions.
As the eAxles generate instant high torque, even at low speed, they are installed with high-stiffness mounts to ensure quietness, ride comfort and stability.
The permanent all-wheel drive (AWD) system provides constant and precise control of drive torque delivery between the front and rear axles, in ratios from 100:0 and 0:100. It provides excellent acceleration at start-off and stable handling. When driving through bends, it supports a smooth change in direction on entry with clear steering feedback, with confident line tracing and acceleration in exiting.
The new battery has been designed specifically for installation within the Hilux's frame. It is a 59.2 kWh water-cooled lithium-ion unit comprising 80 cells, arranged in five 16-cell modules in 5 modules. The battery's location required a bespoke unit to be designed, but the length of the space allowed for the necessary number of modules to be housed.
Its operating temperature is controlled using a high-resistance, long-life coolant (LLC) which helps protect against corrosion and is resistant to conductivity - an important characteristic in high-voltage systems.
Robust battery protection for off-road driving
The requirement for the new Toyota Hilux BEV to be able tackle challenging off-road conditions called for specific measures to protect the battery from damage. A key consideration was the risk posed by excessive twisting forces in the frame when travelling over rough ground. Toyota met this challenge by designing flexibility into the frame and creating a new battery sub-frame that prevents the battery from being affected by torsional forces. The battery is attached to the low torsion area of the subframe by a patented diamond pattern of fastenings.
The battery is further protected by being located within the vehicle's frame and by a robust undercover. The frame's side rails are reinforced with aluminium impact-absorbing sections that provide extra protection in the event of a collision.
CAE simulations and physical testing were used to optimise the battery's location, ensuring a perfect fit within the frame. The battery's position helps secure a low centre of gravity, which in turn supports good stability and handling. The installation avoids intrusion in the Double Cab's interior and load space.
Prompt, consistent charging performance is a key consideration for business customers who need to keep their vehicle's downtime to a minimum. The Toyota Hilux BEV can be charged from 10 - 80% capacity within 30 minutes using a DC fast-charging system of 125 kW or more and CCS2 connection, subject to operating conditions such as the ambient temperature.
AC charging up to 10 kW, for example using a domestic or public wallbox, will deliver a 10 - 100% charge in around 6.5 hours.
Owners can programme smart charging for their Hilux, setting charging start times to suit their work timetable and personal preference, or to take advantage of lower-cost electricity during off-peak periods. They can also set a charging limit of between 50 and 90%.
The driving range is up to 257 km (WLTP combined) and up to 380 km on the city cycle, distances that amply cover the day-to-day requirements of the model's target business customers, particularly for site-specific work such infrastructure installations and forestry.
Quality, Durability and Reliability - QDR - have been fundamental to Hilux's enduring success and global reputation across successive model generations. Toyota's prime concern was that the new BEV should maintain these essential characteristics and be an authentic Hilux, true to the model's best traditions.
Thus, the BEV underwent the same rigorous testing programme as other models in the new Hilux range, together with additional tests specific to its electric powertrain. These included deep-water driving to confirm the pick-up's 700 mm wading depth; high-speed water intrusion checks; off-road durability trials; and total immersion of the battery. To help safeguard against water entering the electric motor, the eAxle breather is set high up on the unit.
With the benefit of these tests, customers are assured Hilux's essential QDR has not been sacrificed or compromised and their vehicle can be relied on - like any Hilux - to serve as a trusted and highly capable partner.
The Toyota Hilux BEV aligns with its mild hybrid sister model in adopting an electric power steering system, as with the Hybrid 48V, the BEV's steering wheel has tilt and telescopic adjustment to help drivers achieve the most comfortable position.
Traditionally, a practical pick-up requires a rigid rear axle so there are minimal changes in alignment when the vehicle is loaded, combined with leaf springs that can maintain a stable ride height.
Introducing a battery electric powertrain into the equation created new challenges. Using a propshaft to the rear axle would compromise the size of the battery and thus the vehicle's driving range; and locating a large rear motor in the space usually occupied by the rear differential would compromise ground clearance and increase the unspring mass, impacting ride comfort and handling stability
Toyota solution is a de Dion rigid axle with leaf springs. This allows the eAxle to be accommodated without risking damage or compromising the pick-up's ability to tackle very rough terrain. As the eAxle can be mounted on the vehicle's frame, there is a further benefit in a reduction in the unsprung mass.
From the outset, it was a requirement that the Toyota Hilux BEV's off-road performance should be comparable to those of other models in the ninth generation series, ensuring the vehicle could meet a wide range of customer requirements.
To do this, it was critical to engineer a rigid rear structure that can withstand challenging conditions. Additional crossmembers were added to the frame and others reprofiled to accommodate the new rear eAxle, together with the introduction of the new de Dion rigid rear axle.
The BEV's 29° approach and 24° departure angles, 500 mm wheel articulation and 700 mm wading depth are values similar to those of other ninth generation Hilux models. There is a lowering of ground clearance to 212 mm and a modest reduction in break-over angle to 20°, due to the location of the battery beneath the vehicle floor.
Ready for all roads with Multi-Terrain Select (MTS)
Hilux is the first Toyota BEV to be equipped with Multi-Terrain Select (MTS), a five-mode electronic control system that automatically adjusts vehicle performance to suit different off-road driving scenarios.
In vehicles that use an internal combustion engine - including the new Hilux Hybrid 48V -MTS can be selected when using the L4 and H4 ranges to secure steady progress in challenging conditions. In the Toyota Hilux BEV, the system applies precise, direct control of drive torque and braking, replicating the effect of using a low range transmission. It underwent extensive real-world testing on different off-road terrains to ensure customers can use it with confidence in a wide range of operating environments.
In common with the standard MTS, the driver can choose settings appropriate for different surfaces:
MTS also provides an automatic mode with which the system adopts the most suitable setting according to vehicle behaviour and driver inputs.
An essential quality for any Hilux is to be a practical and reliable proposition for business users, so the introduction of an electric powertrain could not be at the expense of day-to-day practicality.
The load space is equal to that of the mild hybrid model and the payload is 710-715 kg, according to model grade. This figure was calculated to offer the best balance of driving range, power and practical usability, based on Toyota's extensive evaluation of BEV customer requirements.
Towing ability was factored in from the start of the development programme: the Toyota Hilux BEV can tow up to 1,600 kg, ensuring that it is capable of handling trailers, equipment or leisure loads with confidence.
The BEV shares the ninth generation Hilux's bold, powerful exterior Tough x Agile design, styling that communicates its strength and robust performance.
Externally some elements denote the difference in powertrain. Most prominent is the absence of the front grille - a characteristic of technically advanced electric vehicles which require less cooling air flow. The area beneath the bonnet and TOYOTA emblem instead has a raised geometric pattern that adds texture and distinctive visual interest.
The 17-inch wheels are also specific to the model, lightweight and aero-tuned with a directional design to manage air flow with premium diamond-cut facets around the circumference. Simulations and wind tunnel testing optimised the design for efficiency at all speeds. Elsewhere, the wheel arch mouldings are removed, there is BEV badging on the tailgate and a charging port on the front wing.
The Double Cab interior is also common to the Hilux range, with the exception of the centre console, which is slightly adapted to accommodate the BEV's smooth, single-action shift-by-wire control and repositioned electronic parking brake switches.
The 12.3-inch driver's digital combimeter offers the same flexibility as that in the Hybrid 48V, with four design options - Casual, Smart, Tough and Sporty. The driver can choose from three layouts, displaying two, one or no dials; widgets can also be added to show electricity consumption and audio information. Settings and content can be changed at any time with ease, using switches on the steering wheel.
