Updated: May 2010
TOYOTA HILUX
KEY POINTS

Sixth generation of the legendary Toyota Hilux

Europe’s best-selling pick-up

More power and torque and revised specifications for 2010 model

Maximum power from 2.5 D-4D engine increased by 20 per cent to 142bhp,
maximum torque raised to 343Nm

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 the Magnetic North and South Poles

Independent double wishbone front suspension

Rear differential lock standard on all 2.5-litre models

Automatic Disconnecting Differential standard on all grades

Vehicle Stability Control standard on flagship Invincible grade

Single Cab, Extra Cab and Double Cab body styles

Selectable four-wheel drive, with shift-on-the-fly facility

Three grades – HL2, HL3 and Invincible

ABS and driver and front passenger airbags, air conditioning, electric windows
and remote central locking standard on all versions
INTRODUCTION
The sixth generation of Toyota’s legendary Hilux was launched in 2005, marking a
substantial leap forward in performance and design, giving the mighty pick-up more
load-carrying capacity, more space and comfort in the cabin and a more
contemporary and distinctive appearance.
That package was further strengthened with the subsequent introduction of new
common rail 2.5 and 3.0 D-4D turbo diesel engines, delivering stronger performance,
improved efficiency and lower emissions. These combine with refined manual and
automatic transmissions and a strong and rigid construction to give the Hilux
surefooted performance both on and off-road.
For the 2010 model year the 2.5-litre unit has been given a substantial upgrade:
output has been increased by 20 per cent, from 118 to 143bhp, and maximum torque
is also greater, at 343Nm. The engineering tweaks, which focus on new turbocharger
and fuel injector designs, also bring improvements in acceleration and top speed, but
not at the cost of any increase in CO2 emissions.
More than ever before, Hilux has the essential qualities to appeal beyond the work
marketplace to customers looking for a vehicle that’s ideal for leisure and family
transport, too.
HILUX TIMELINE
YEAR MONTH
1972
2004
February
July
2005
October
2006
November
2007
January
May
2008
July
2008
2009
November
January
November
EVENT
Hilux is introduced to the UK market.
ABS and driver’s airbag made standard on all Hilux models.
The Invincible model is added to the range.
All-new sixth generation Hilux launched in the UK.
The Extra Cab model is introduced, together with the 2.5 D-4D
120 engine.
The 3.0 D-4D 170 is added to the range; all engines now meet
Euro IV emissions standards.
Hilux becomes the first car to be driven to the Magnetic North
Pole, driven by Jeremy Clarkson and James May for the BBC
Top Gear television programme.
Toyota launches Hilux Invincible 200, a limited edition model. A
Toyota Motorsport diesel engine performance kit increases output
to 195bhp, making the Invincible 200 Britain’s most powerful
production pick-up
Introduction of first 2009 model year Hilux.
3 Toyota Hilux driven to South Pole as ski race support vehicles
2010 model year Hilux announced with increased power and
torque from revised 2.5 D-4D engine.
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.
The engine delivers 169bhp at 3,600rpm and has a torque output of 343Nm all the
way from 1,400 to 3,400rpm.
In models fitted with five-speed automatic transmission torque is boosted by 17Nm to
give a maximum 360Nm between 1,400 and 3,400rpm.
Top speed is 106mph (109mph auto) with fuel consumption of 34mpg in combined
cycle driving (31.7mpg auto).
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 counterrotating 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.
Further improvements to the engine’s emissions performance have been achieved
by fitting 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.
The 3.0-litre D-4D engine is available in the Hilux Double Cab Invincible, with fivespeed manual or automatic transmission.
2.5-litre D-4D
The 2.5-litre D-4D engine was further improved for the 2010 model year to deliver
even more power and torque, without compromising emissions performance.
Well-established as the core power unit for the Hilux range, it now produces 20 per
cent more power, up from 118 to 142bhp at 3,600rpm, and six per cent more torque,
with the maximum increased from 325Nm to 343Nm. This gives the Hilux an
excellent balance of flexible driving performance and low fuel consumption.
The power increase has been achieved by adopting a new variable nozzle vane-type
turbocharger, activated by a DC motor, and new fuel injectors that operate with
greater precision, improving throttle response and performance.
Engine performance is supported by an intercooler, ad 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, improvements in emissions performance have been
achieved by fitting an EGR cooler. These changes, and adjustments to the catalytic
converter, ensure the engine complies with Euro IV emissions standards.
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.
Compared to the previous four-speed system, combined cycle fuel consumption was
improved, from 30.1 to 31.7mpg.
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.
LEGENDARY 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 four 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 26 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 2,250kg for both engines.
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 6.1m
turning radius.
STYLED FOR A CHANGING MARKET
Hilux is easily identified by its trapezoid front grille with a grey metallic plate bar
bonnet air scoop and, on HL3 and Invincible models, round front fog lamps are set
into the outer corners of the bumper. Fifteen and 17-inch alloy wheels are featured
on the HL3 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.
Hilux is available in six colours: Pure White, Eclipse Black metallic, Kielder Green
metallic, Silver Steel metallic, Sunburst Red and new Island Blue metallic.
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 2,315mm for the Single Cab, 1,805mm for
the Extra Cab and 1,520mm for the Double Cab.
Equipment specifications
The Hilux is available in three body styles – Single Cab, Extra Cab and Double Cab and three grades – HL2, HL3 and Invincible – which reflect the vehicle’s ability to
satisfy the needs of those owners focusing on work use and those looking for extra
features that make it a strong performer as recreational or family transport.
HL2 versions are equipped with air conditioning, remote central locking, locking
tailgate (not Single Cab), electric windows, ABS and a sound system combining
radio and CD player, with MP3 CD-R compatibility on HL2 and HL3 models.
HL3 grade models additionally feature overfenders, a body-coloured grille and front
bumper, chrome door handles, rear step, and side steps, electrically adjustable
heated door mirrors, front fog lamps, 15-inch alloy wheels, leather steering wheel
and gearshift trim, dark-tinted rear privacy glass and a Thatcham Category 1 alarm.
The flagship Hilux Invincible is equipped with17-inch alloys, chrome side running
bars cruise control, driver and front passenger side airbags, curtain airbags,
premium-style front seats and automatic air conditioning.
The HL3 and Invincible specifications can be extended with a wide range of
dedicated accessories including a Sport Deck and an Urban Pack, which comprises
a front guard, scuff plates and front and rear parking sensors. Satellite navigation
and Bluetooth are available as options on HL3 and Invincible models with two-tone
leather upholstery additionally available for the Invincible.
EXTRA CAB, EXTRA APPEAL
The Extra Cab focuses firmly on practicality and is aimed principally at the business
user who needs the flexibility of additional passenger space with maximum load area.
It’s a two-door model, but features two occasional rear seats, equipped with three
point seatbelts. These are incorporated into the design allowing a rear deck length of
1,805mm compared to a Double Cab’s 1,520mm.
A single version is offered, in HL2 specification, powered by the 2.5-litre D-4D engine
with five-speed manual transmission. Standard features include air conditioning,
electric windows, remote central locking, ABS and driver and passenger front
airbags, demonstrating Toyota’s commitment to offering both tough performance for
work and high levels of comfort, convenience and safety.
INSURANCE GROUPS
GRADE
BODY STYLE
ENGINE & TRANSMISSION
HL2
HL2
HL2
HL3
Invincible
Invincible
Single Cab
Extra Cab
Double Cab
Double Cab
Double Cab
Double Cab
2.5 D-4D 5MT
2.5 D-4D 5MT
2.5 D-4D 5MT
2.5 D-4D 5MT
3.0 D-4D 5MT
3.0 D-4D 5AT
Ref: 100701N
INSURANCE
GROUP
8A
9A
9A
10A
10A
10A