camioneta hilux

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www.toyota-media.com

2007 Toyota HiluxDynamic Press Launch, Kwazulu Natal

Toyota Hilux Kwazulu-Natal Raid

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The 2007 Toyota Hilux 4A true work & leisure vehicle

Powerful new diesel engines �0

Choice of smooth transmissions �8

Legendary off-road performance �4

Evolving to exceed market expectations ��

Toyota IMV: a truly global project �8

Specifications and equipment table 44

An active investor in South Africa 54

Toyota Hilux Kwazulu-Natal Raid 60

Appendix: new TSAM paint plant 70


4 5


The �007 Toyota Hilux


6 7


The �007 Toyota Hilux A true work & leisure vehicle

• Great off-road capability with on-road comfort and refinement

• High performance �.0-litre D-4D with �7� DIN hp and �4� Nm of torque

• Current �.5-litre D-4D boosted to ��0 DIN hp and ��5 Nm of torque

• Introduction of a new automatic transmission

• Premium grade SR-X available in selected markets

The �007 Toyota Hilux is launched with a powerful new range of diesel engines and styling

enhancements to offer today’s customers a pick-up that will truly suit their choice of work, leisure

or adventure lifestyle.

The �007 Toyota Hilux offers outstanding performance, both on and off-road. And the new

engines and improved specification enhance driving pleasure so the latest generation Hilux offers

even higher levels of comfort and refinement. The changes will help Hilux to become one of the

top selling pick-ups across Europe with strong customer appeal in both the leisure and utility

vehicle markets.

Kaoru Hosokawa, Executive Chief Engineer for Hilux says: “Toyota Hilux stands for quality,

durability and reliability. In the latest model we want to build on other attributes which were first

introduced in �005, such as SUV-like driving performance, a new engine line-up, a more rugged

look and enhanced interior specification.”

The new engines include a high performance, high torque �.0-litre D-4D diesel which will give the

Hilux a balance of on-road performance aligned with off-road capability and help it compete in the

growing leisure pick-up segment of the market. The selected introduction of this �7� DIN hp unit,

based on the Toyota Land Cruiser’s engine, will give the Hilux market-leading power to weight

ratio and outstanding performance driving characteristics.

At the same time the current �.5-litre D-4D diesel engine has been upgraded to develop ��0 DIN hp,

a seventeen per cent increase on the current unit, and a remarkable torque of ��5 Nm. This

new �.5-litre D-4D will replace the current �0� DIN hp option to offer customers a single, highly

responsive power unit, suitable for both leisure and utility markets.

Both new �.0 and �.5 litre engines comply with stringent Euro IV emissions regulations and the

new line-up offers Hilux customers an excellent balance of driving pleasure, low fuel consumption

and low emissions.

Starting in Q4 �006, the �007 Hilux is available with a choice of transmissions – a four speed

automatic is now optional on the �.0-litre D-4D models alongside the five-speed manual across

the range. The new hi-tech automatic gearbox features ‘Artificial Intelligence’ shift control to

respond to driving conditions and -style.

Product evolution and enhancements

• More rugged exterior styling

• Hi-tech Optitron meters (�.0 D-4D)

• New premium SR-X grade in selected markets

At the same time as the increased performance, the appeal of Hilux is further enhanced with

a series of styling changes and specification improvements. These evolutionary changes to an

already highly successful model establish a more premium position for Hilux in the leisure and

adventure market.

The �007 Toyota Hilux also gets a more rugged look, with the addition of an air scoop on the

bonnet to increase air-flow for the intercooler and front fog lamps on SR grade models and above.

A more hi-tech interior ambience is created with new, Optitron meters exclusively for the �.0-litre

D-4D model, which also receives a multi-information display and shift position indicator

(automatic transmission only).

This premium positioning is further emphasised by the launch of a new flagship grade, the SR-X,

in selected markets. Available only with the �.0-litre D-4D, the Hilux SR-X will appeal to customers

wanting to maximise the premium leisure status of their Hilux with features such as full leather

interior trim, full-map DVD-based navigation, unique alloy wheels and chrome side bars.

There will also be more customer choice in the range with the introduction of an Extra Cab model

for right hand drive markets in 4x4 configuration.


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Worldwide sales success

• Best selling Toyota off-roader

• Sales leader in global markets

• Key model in global IMV project

• Increased European sales target for �007

The current Toyota Hilux, launched in Europe in late �005, is the sixth generation of Toyota’s second

best selling model worldwide and its best selling off-roader. Indeed, more than �� million units have

been built since the Hilux was first introduced in Japan in ��67.

On a global scale, the new Hilux was the best seller in South Africa, Australia, Thailand, Brazil and

Argentina in �005, while it was also the best selling pick-up vehicle in three European countries

(Denmark, Finland and Norway). By the end of July in �006, the Hilux reached a cumulative production

of 6��,6�7 units.

The Hilux is one of three vehicles being developed under Toyota’s IMV (Innovative International Multi-

purpose Vehicle) project. IMV products are truly global vehicles designed to sell in more than �40

countries and to meet modern customer demand for high levels of quality, durability and comfort.

Five countries within the Toyota global manufacturing network (Thailand, South Africa, Argentina,

Indonesia and India) are charged with full vehicle production in excess of 650,000 units per year by

the end of �006, with Toyota South Africa Motors (TSAM), the lead plant in Durban, supplying Hilux

Double Cab and Single Cab to the European market.

The final �006 volume projection for South African manufacture was for 86,000 IMV vehicles but the

success of the IMV platform since its introduction has led to an increase in global sales volume forecasts

by Toyota. On a world-wide basis, demand has been exceeding supply and consequently, in �006,

due to this supply restriction, Toyota has limited its sales in Europe to ��,000 units. Recently increased

production capacity to ��0,000 units a year at TSAM in �007 now means the European sales target will

rise to �4,000 units.

“For over �5 years, Hilux has built a legendary reputation as a tough, reliable workhorse,” says Andrea

Formica, Senior Vice President Sales, Marketing & After-Sales, Toyota Motor Marketing Europe. “Today,

Hilux is much more. Its unstoppable ability comes with more refinement, more equipment and more

power making it the ultimate leisure and adventure vehicle. The �007 Hilux will become an even

stronger volume and image contributor to our continued SUV-leadership position in Europe.”


�0 ��


Powerful new diesel engines


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Powerful new diesel engines• More power and torque for outstanding performance

• Broad choice to suit customer demand

• All diesels now Euro IV compliant

The powerful new diesel engine range in the �007 Toyota Hilux, and the option of automatic

transmission on the new �.0 D-4D engine, offers customers a broad choice of powertrain to suit

their work and leisure needs.

The new engines are refined and quiet, with high torque output for maximum power both on- and

off-road. They deliver smooth power throughout the rev range and, thanks to high efficiency

turbochargers, balance this increased power output with low fuel consumption and reduced

emissions.

Both engines comply with Euro IV emissions and have been integrated into the Hilux range to

enhance driving pleasure, especially in the growing leisure pick-up market.

Outstanding performance: 3.0 D-4D

• D-4D engine from Land Cruiser

• Second generation common-rail

• Compliant with EURO IV emission standards

• Ultimate leisure and adventure choice

The new �.0-litre D-4D in the �007 Hilux is the latest derivative of the renowned diesel engine

which also appears in the flagship Toyota Land Cruiser. It features second-generation common-rail

technology, variable nozzle turbocharger and a swirl control system for maximum efficiency.

Equipped with this hi-tech advanced engine, the Toyota Hilux is the ultimate leisure and

adventure vehicle with outstanding off-road capability while also delivering refined on-road

driving pleasure with low levels of noise, vibration and harshness.

In its latest derivative the �.0 D-4D (�KD-FTV engine) delivers �7� DIN hp (��6kW) of power

at �,600 rpm and has a flat torque output of �4�Nm right across the engine range from �,400

to �,400 rpm. This engine gives the �007 Toyota Hilux at top speed of �70 km/h (M/T) while

delivering excellent fuel economy of 8.� l/�00km (M/T) on the combined ECE-cycle.

Engine performance curve 3,0 D-4D

150

500 1000 1500 2000 2500

Engine speed (rpm)

Out

put

Torq

ue

3000 3500 4000 4500

200

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

250

300

350

400

450

500(Nm) (kW)


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The �.0-litre engine is a technically advanced iron-alloy block unit with an aluminium alloy cylinder

head and four valves per cylinder. Two separate input ports of different shapes help promote fuel

mix and optimise swirl.

The five journals crankshaft has eight balancing weights and there are two counter-rotating

balancing shafts to reduce engine vibration, contributing to the excellent driving pleasure. The

engine mounts, front and rear, have been optimised to reduce vibration transmission to the chassis

and enhance ride comfort.

The second-generation, common rail system develops a high injection pressure, allowing the use of

injector nozzles with smaller diameter holes to create a more homogenous air-fuel mix, improving

the efficiency of the combustion process. This translates into more performance with lower

emissions and lower fuel consumption.

Over a wide range of engine speeds (800-�000 rpm) the common-rail system performs a double

pilot injection per cycle (prior to the main injection), distributing the most suitable amount of fuel

with three distinct injections each. This reduces the combustion noise and engine vibration, from

this high performance diesel.

One key to the impressive power and torque output of the �.0-litre D-4D is the sophisticated,

variable vane, turbocharger which balances exhaust back pressure and boost pressure based on

the precise demands of the engine. Toyota uses an electric DC (direct current) motor to activate

the variable nozzle vane mechanism, instead of the conventional step motor. The result is sharper

response from the turbocharger, particularly at lower speeds and higher precision of vane

activation.

The engine also benefits from a Swirl Control System. Each cylinder is supplied with air/exhaust gas

mixture through two different independent ducts. Butterfly valves operated by the Swirl Control

System can shut off one of these ducts according to the engine speed and load, increasing the

mixture’s swirl rate.

Further improvements to the emissions performance, particularly at cold start, are achieved by

fitting an Exhaust Gas Recirculation (EGR) cooler with integrated bypass and a switching valve to

optimise EGR gas temperature.

Swirl control system

Actuator

Swirl control valve

EGR

EGR gas inlet EGR gas outlet (cooler side)

EGR gas outlet (bypass side)

Switching valve


�6 �7


At low engine speeds this device improves the air-fuel mixture, thus further increasing torque

availability at low speeds along with lower emissions.

The new �.0 D-4D engine will be exclusively available for the 4x4 Double Cab body style in SR

grade and above.

The new Hilux �.0 D-4D Double Cab will go on sale in selected markets across Europe in December

�006.

Power boosted: 2.5 D-4D

• Power up by �7%

• Intercooler improves efficiency, reduces emissions

• Now compliant with Euro IV emissions standards

• More refinement with lower noise and vibration

More power, reduced emissions and lower noise levels are key enhancements to the �.5-litre

D-4D engine that remains at the heart of the Toyota Hilux appeal and have made it a best-seller

worldwide. The power-boosted �.5 D-4D, with remarkable torque output, will give the �007 Hilux

more performance and more driving pleasure.

Maximum engine power of the �.5 D-4D has been increased by seventeen per cent to ��0 DIN

hp (88kW) at �,600 rpm with the introduction of a high performance turbo-intercooler and other

developments. As a result top speed is now �65 km/h (4x� manual transmission) and �55 km/h for

4x4 version.

At the same time the torque output from this engine is now at ��5 Nm. Torque output is above

�00 Nm from �600 rpm to �600 rpm, giving the �.5-litre D-4D Hilux a very good balance

between excellent driving pleasure and low fuel consumption in real world driving conditions. On

the combined cycle, the �007 Hilux �.5-litre D-4D will deliver from 7.4 l/�00 km to 8.�l/�00km,

depending on the model.

The high performance, lightweight intercooler is positioned above the engine for maximum effect.

It not only increases power but also offers enhanced emissions performance. Low speed torque is

boosted by the inclusion of a two-stage swirl control valve, similar to the �.0 D-4D, in the intake

manifold which improves the swirl rate at low intake pressures.

Engine performance curve 2,5 D-4D

150

500 1000 1500 2000 2500

Engine speed (rpm)

Out

put

Torq

ue

3000 3500 4000 4500

200

0

10

20

30

40

50

60

70

80

90

100

250

300

350

(Nm) (kW)

Just as with the �.0-litre engine, additional improvements to the emissions performance are

achieved by fitting an Exhaust Gas Recirculation (EGR) cooler with integrated bypass and a

switching valve to optimise EGR gas temperature.

These changes, and optimisation of the oxidation catalytic converter, ensure that the �.5-litre D-

4D is now fully compliant with Euro IV emissions standards.

The �.5-litre D-4D Hilux also offers customers excellent refinement and low noise levels, thanks

to a series of measures to reduce noise and vibration. As with the �.0-litre D-4D, improvements

to the combustion process allow the compression ratio to be reduced to �7.4:�, giving more

performance and reduced noise.

A large engine cover enhances the appearance and cuts radiated noise while urethane foam

insulator is effectively used in selected areas to reduce noise.

The �.5-litre D-4D engine remains at the core of the Toyota Hilux range and will continue to be

available in 4x� and 4x4 configurations (depending on national markets) and in Single Cab, Extra

Cab and Double Cab body styles. The engine is available with a five-speed manual transmission.

Sales of the more powerful �.5 litre D-4D starts during the fourth quarter of �006 and will be

phased, depending on body type.


�8 ��


Choice of smooth transmissions


�0 ��


Choice of smooth transmissions• Introduction of a four-speed automatic widens choice

• Smooth gear shifts

• ‘Shift on the fly’, part-time 4-wheel drive system

The �007 Hilux range offers increased driving pleasure and customer choice with the option of an

advanced four-speed automatic transmission with �.0 D-4D models. The four speed automatic,

which is based on the flagship Toyota Land Cruiser, will be offered in addition to the current five-

speed manual gearbox on Double Cabs.

The option of four-speed automatic transmission on Hilux is a further example of how Toyota’s

worldwide 4x4 experience can add customer benefits across the model range. The four-speed

automatic gives the Hilux excellent performance, on and off-road, with super-smooth, gear

changes.

The automatic gearbox continues to offer Hilux drivers a full range of drive options including ‘shift

on the fly’ changes between four wheel drive and two-wheel drive, as well as Toyota’s Automatic

Disconnecting Differential (ADD). This feature automatically engages or dis-engages the front

differential depending on the selected drive mode, even when the vehicle is moving, resulting in

improved fuel efficiency and lower noise levels. The Hilux is equipped with a part time four wheel

drive system operating the rear in two wheel drive mode until the four wheel drive is engaged for

off-road and other adverse driving conditions.

Four speed automatic

• Electronic transmission control with Artificial Intelligence

• Super smooth gear changes

• Excellent vehicle control, on and off-road

This four-speed automatic transmission in the �007 Hilux was originally developed for the current

Land Cruiser range and offers true flagship features. It is an electronic controlled transmission

with Artificial Intelligence (AI) – meaning that it can adapt the gear shift pattern to suit driving

conditions such as driver input or road conditions.

Al-shift

Input SignalAI-SHIFT

Position sensorBassic shiftpattern control

Road conditionsupport control

Driver’s intensionsupport control

Road conditions

Driver’s intention

Uphill/Downhill driving

Calculated by ECU Accelerationpedal operation

Estimating driver’sintention

Criterionacceleration

Actualacceleration

Greater

Greater

Smaller

• Throttle opening angle

• Vehicle speed

• Vehicle acceleration

• Engine speed

• Brake signal

Estimating grade

Vehicle condition


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The gearbox will also respond to local terrain, such as steep uphill or downhill sections by holding

gears to ensure optimum vehicle control.

The onboard computer can also recognise any minor malfunctions in the automatic transmission

and record these for future diagnostic analysis during routine maintenance.

Super-smooth, gear changes are achieved by computerised engine torque control which

momentarily reduces engine speed during gearshifts to reduce torque peaks.

The transmission is controlled by a cable-type shift operator and the gate-style shift lever adds to

the sporty image of the Hilux with smooth changes through the gear settings.

Five speed manual

• Refined driving performance

• Improved shift feel

• Synchro on reverse

The five speed manual gearbox offers refined driving performance, both on and off-road, with

smooth gear changes and excellent fuel consumption. The transmission is particularly tuned for

off-road climbing and descending where it gives outstanding control over engine braking and

vehicle speed. The Hilux is especially smooth at tick-over (‘walking speed’) which makes driving

in �st gear on engine idle a controlled experience without the need for keeping a foot on the

accelerator. It is nearly impossible to stall the vehicle.

Improvements to the Hilux which were already introduced in the �005 model, have resulted in

a transmission which is smoother and easier to use, leading to a better gear change feel. A total

of 4� parts were refined to reduce friction, decrease forces and increase precision for maximum

comfort.

In particular, a triple synchromesh cone has been adopted on both first and second gears and the

addition of a synchoniser on reverse gear avoids all grating noise when engaging reverse. At the

same time it prevents mis-shifts in many cases.


�4 �5


Legendary off-road performance


�6 �7


Legendary off-road performance• Hilux retains rugged quality

• Remarkable off-road performance

• �.0 D-4D is ultimate leisure and adventure vehicle

Outstanding performance is a key feature of the �007 Toyota Hilux. With its wide range of

applications, from family leisure vehicle to tough, off-road workhorse, the Hilux needs to satisfy a

wide range of demands from today’s customers.

But, underneath that modern concept, the Hilux retains the rugged quality features that have

made it a legendary success around the world – including truly remarkable off-road performance.

The Hilux is built on a traditional ladder frame chassis which is 45% stiffer than the previous

generation model. The specially designed TOP platform (Toyota Top Performance) features

strengthened cross-member joints for increased frame rigidity, adding to the all-round robustness

which Hilux has become famous for. This not only allows the vehicle to achieve genuine off-road

capability and maintain durability in some of the harshest environments around the world, but

also offers better noise and vibration insulation between the passenger compartment and the

chassis – reducing NVH and improving ride comfort. The chassis side rail section stiffness has been

increased by 75% with an additional �0 mm of height and �0 mm of width.

The independent front suspension and conventional rear leaf springs have been designed to

operate in the harshest terrain, while still providing comfortable ride and great direction control

when on-road.

But it is both the powerful new �.0 D-4D and the upgraded �.5 D-4D engines that allow the �007

Hilux to most clearly demonstrate its off-road capabilities. With their high torque output across

a wide engine speed range, the Hilux lets the driver extract optimum performance at any speed,

across any terrain.

Both the �.0- and �.5-litre D-4D manual transmission are especially smooth at tick-over (‘walking

speed’) which makes driving in �st gear on engine idle a smooth and controlled experience. This

allows steep descents in rugged terrain to be made without losing control of the vehicle while the

superior control and high torque output means Hilux can equally climb steep slopes on engine idle

only.

The ground clearance of 4x4 Hilux models is excellent (�� mm) and it has large approach and

departure angles (up to �0° and �6°, respectively) allowing it to easily tackle steep inclines. The

ramp breakover angle is �5°.

Hilux approach angle

30°25°26°

The new Hilux offers increased load space, up by �5% over the previous generation Double Cab

model. The towing ability has a maximum brake towing capacity of �,�50 kg for both the �,5 litre

and �,0 litre engine.

Superior traction control

• Proven technologies for effective traction

• ‘Shift on the fly’, part-time 4-wheel drive system

• Front Automatic Disconnecting Differential (ADD)

• Rear Limited Slip Differential (LSD) for on- and off-road traction

• Rear Differential Lock (DIFF LOCK) for tougher off-road use

The �007 Toyota Hilux uses proven yet refined technologies to develop superior control in

extreme off-road and on-road conditions. These technologies offer more effective and more

practical solutions to control and extract the vehicle from difficult terrain than other, often

electronic, devices.


�8 ��


Hilux 4x4 system allows the driver to shift out of four wheel drive (from H4 to H�) with no speed

restriction and into four wheel drive (from H� to H4) at speeds up to 80km/h. For really tough off-

road driving the synchronised shift mechanism allows to shift from H4 to L4 (or vice-versa) without

stopping the vehicle at speeds up-to eight km/h.

4 x 4 Transfer Case

Panetary Gear Unit Front Drive Gear PieceFront Drive Clutch Sleeve

Front Drive Hub

Rear Output Shaft

Shift Pattern

Silent Chain

Oil Pump

Transfer Input Shaft

Front Driven Sprocket

The Hilux uses a central drive unit with a silent chain for the front wheel torque delivery, including

a planetary gear set (reduction ratio �.566). The planetary gear drive (H�/H4) rotates in one piece

whilst in reduction (L4) the torque flows over the pinion gears and the planetary spline carrier.

Planetary Gear System

Panetary Ring Gear

Pinion Shaft

Planetary Pinion Gear

Planetary Sun Gear

High and Low Clutch Hub

High and Low Clutch Sleeve

High and Low Clutch Sleeve

Planetary Carrier

Planetary Spline PieceTransfer Input Shaft

Planetary Pinion Gear

Planetary Ring Gear

Rear Output Shaft

Transfer Input Shaft

Planetary Carrier

Planetary Spline Piece

With the SR and SR-X 4x4 grades comes Toyota’s advanced Automatic Disconnecting Differential

(ADD) as a standard feature. This automatically engages or dis-engages the front axle drivetrain

with the shift from four to two wheel drive. As such, ADD contributes to a better fuel efficiency

and lower noise levels in �WD drive conditions. The ADD shift actuator is located outside the Hilux

front differential.

Front Differential

A.D.D. Shift Actuator

LH Propshaft

Drive Shaft

RH propshaft

Hilux comes fitted with a Limited Slip Differential (LSD) at the rear axle designed to provide

traction off-road and even minimise wheel spin when travelling on-road. The LSD is standard

equipment in the rear axle in selected markets to transfer torque away from a slipping rear wheel

and provide best possible traction. The LSD automatically distributes the necessary balance of

torque between the left and right rear wheel and gives torque to the one wheel with the higher

traction. This enables the Hilux to driving more smoothly and steadily during cornering and over

extremely rough ground, in the most slippery conditions.

Also available on selected grades is an optional rear Differential Lock for tougher off-road use.

The Differential Lock employs via electrical switch an axle mounted motor drive to lock the rear

axle differential. This prevents transfer between left and right rear wheels, enabling traction and

control to be maintained even if one rear wheel lifts in the air.

The Differential Lock is designed for more experienced off-road drivers and is activated manually

by pressing a button on the dash board.


�0 ��


Advanced suspension design

• High speed stability and secure feel

• Excellent ride comfort, even on rough ground

• Agile and precise steering

The suspension of the Toyota Hilux has been designed to offer great handling performance both

on and off-road while still delivering comfortable ride and excellent straight line stability.

The independent front suspension with coil springs and double wishbones enables the Hilux to

have excellent bump absorption while maintaining excellent steering feel and ride comfort. The

suspension features a low-mount upper arm on 4x� models and a high-mount upper arm on the

4x4 version.

Hilux chassis with suspension

The front suspension geometry is optimised for straight line stability with increased caster angle

and a smaller kingpin offset for good braking stability. Suspension bushes are stiff in order to

withstand bending moments.

In order to improve the roll feeling and reduce body roll angles, the shock absorber damping has been

increased and the anti-roll bar is connected to the upper suspension arm using ball joints for greater

rigidity. Coil springs are fabricated from stiffer, high tensile steel to reduce the unsprung weight.

At the rear, a conventional yet highly precise, leaf-spring suspension, with its typical spring rating,

is retained to avoid intrusion in to the cargo deck and to provide a flat ride, especially when the

Hilux is running with light or no load. The suspension settings have been optimised for all driving

conditions.

In order to achieve excellent stability and steering feel on-road, the Hilux uses power assisted rack

and pinion steering with increased steering frame structure for improved torsional stiffness. This

means the Hilux can be stable and agile for highway driving while still allowing strength and good

bump absorption off-road.

The steering is notable for transmitting very few vibrations in off-road conditions, yet still being

very positive and direct with positive feedback on-road.

The new Hilux is more agile than the previous generation model with a very compact turning

radius of just 5.�m for the 4x� version and 6.�m for the 4x4.


��


Evolving to exceed market expectations


�4 �5


Evolving to exceed market expectations• More powerful exterior design

• More space and more road presence

• New, premium grade SR-X

• Increased load deck capacity

The appeal of the �007 Toyota Hilux is enhanced by styling changes to give a more rugged look.

These include the addition of an air scoop on the bonnet which also has the practical benefit

of increasing air-flow for the intercooler and front fog lamps on SR grade models and above.

These are integrated into the outer corners of the deep front bumper to emphasise the sporting

characteristics of the vehicle.

At the same time, the latest Hilux will be available in several additional exterior colours designed to

emphasise the powerful body, including Night Sky Black, Stellar Blue and Stone Grey.

Night Sky Black Stellar Blue Stone Grey

A key selling point of the current generation Toyota Hilux is its modern design, offering superior

quality and significant improvements in interior space and modularity. Frontal styling is bold and

aggressive with the deep front bumper and massive bonnet adding to the sense of authority.

As for the recent �005 Hilux model, it was quite clearly designed to be ‘one-size up’ from the

previous model to give it more road presence and satisfy contemporary customer demands with

a substantial improvement in interior space. For instance, the cabin length on the Double Cab has

been increased by �5 mm and the driving position moved forward to allow an extra 4� mm of rear

leg room versus the previous model.

The load deck is more spacious, particularly in Single and Double Cab versions and the Single Cab

deck now has �5% more load carrying capacity than the previous generation model. Total load

lengths are now �,��5 mm for the Single Cab and �,5�0 mm for the Double Cab. The Extra Cab

load length is �,805 mm.


�6 �7


New premium model grade

• The ultimate leisure and adventure vehicle

• Available only with �.0 D-4D

• Tailored leather interior

• Full-map DVD-based navigation and unique alloy wheels

The premium positioning of the Toyota Hilux as the ultimate leisure and adventure vehicle is

further emphasised by the launch of a new, flagship grade, the SR-X, in selected markets.

Available only with the �.0-litre D-4D, the Hilux SR-X clearly demonstrates how Hilux has evolved

into the ultimate leisure and adventure vehicle. It also demonstrates the superior quality and class-

leading engineering of the vehicle.

Standard features on the Hilux SR-X include tailored leather interior with seat, door panels, steering

wheel and gear knobs showing nice-to-touch leather-trim, the Toyota DVD-based navigation

system with touch screen and dynamic route guidance, unique alloy wheels and eye-catching

chrome side-bars.Enhanced equipment levels

• SUV-style comfort and refinement

• Hi-tech Optitron meters on �.0 D-4D

• Premium level options on high grades

Equipment levels (varying by model and market) on the �007 Hilux reflect the wide choice

expected by customers who are looking for SUV-style comfort and refinement within a rugged,

pick-up context.

Typical is the new four-speed automatic gearbox, now optional with the high performance �.0-

litre D-4D engine. Models equipped with the automatic transmission also get cruise control as

standard and gain a shift position indicator in the meter console.

The hi-tech and high quality feel of the Hilux �.0 D-4D is further enhanced by the Optitron

meters, derived from high grade, sports performance models in the Toyota range.

Included in the list of newly available options is full map, DVD-based navigation with touch-screen

and dynamic route guidance. This clear, easy-to-use system provides precise navigation across

all European countries and will suggest alternative routes if traffic congestion builds up on the

original choice (subject to local national licensing). The DVD-navigation also integrates the audio

system with radio, CD and MP� player.


�8 ��


Toyota IMV: a truly global project


40 4�


Toyota IMV: a truly global project• Hilux one of three innovative International Multi-purpose Vehicles (IMV)

• Designed to sell in more than �40 countries

• Economies of scale with highest quality

The current generation Toyota Hilux is one of three vehicles developed on a global basis under

Toyota’s innovative International Multi-purpose Vehicle project (IMV). The full IMV line-up consists

of three versions of the Hilux pick-up, a mini-van named Innova, and a Sports Utility Vehicle named

Fortuner. The last two are only available outside of Europe.

Toyota’s IMV project has, as its core concept, an optimised global production and supply system

for a range of pick-ups and multipurpose vehicles. IMV products are designed to sell in more than

�40 countries and to meet modern customer demand for high levels of quality, durability and

comfort.

The IMV project represents an unprecedented manufacturing approach under a “Made by Toyota”

banner. This new manufacturing approach draws on the resources and potential available in the

Toyota global network outside of Japan for the supply of fully built up vehicles and components.

The vision for the IMV platform was to have the vehicle perform equally as well on paved and

unpaved roads, to be affordable and at the same time to provide unmatched satisfaction in terms

of comfort, styling, handling, safety, fuel economy and environmentally-friendliness.

Kaoru Hosokawa, IMV Executive Chief Engineer, explains: “We wanted to create a range of vehicles

with quality, performance and reliability that is more than suitable for the most demanding global

markets and, at the same time, to minimise locally specific features. This gives us economies

of scale based on volume production but we are still able to adjust some features, such as ride

comfort and equipment, to suit local markets.”

The sales success of the new Toyota Hilux, which accounts for 66% (FY�005) of IMV production,

is on a global scale testament to effectiveness of the IMV project. In �005 the Hilux was the best

seller in South Africa, Australia, Thailand, Brazil and Argentina and already the best selling pick-up

in three European countries: Denmark, Finland and Norway.”

Five countries within the Toyota global manufacturing network - Thailand, Indonesia, Argentina,

India and South Africa - are charged with full vehicle production in excess of 650,000 units per

year by the end of �006. In addition to these global IMV manufacturing bases, many other

countries world-wide are charged with the manufacture of components for the IMV project and

production for local markets.

Level of quality

• Rapid feedback to local production

• Close co-operation on development

• Active discussion with local suppliers

The IMV concept not only benefits the global economy but it has practical quality and durability

benefits too. With vehicles produced in some of the most demanding off-road markets in the

world, there is rapid feedback from customers and Toyota engineers to continuously improve

vehicle quality. Any possible problems which arise in the local market are very rapidly fed back to

the production line.

IMV means there is no longer a ‘master vehicle’ produced in Japan, but Toyota production quality

has been maintained through a series of measures.

Kaoru Hosokawa, IMV Executive Chief Engineer, explains: “During the development phase we

performed simultaneous engineering activity involving manufacturing, purchasing and even

working with suppliers to discuss what materials were available locally and how best to adapt

local production processes. We had to adapt the production technology to the highest common

denominator that would allow us to achieve the high quality expectations in all manufacturing

countries.

“Moreover, we have promoted an active discussion with Toyota’s local sales and marketing

representatives to determine which specifications best suit each market. At the stage prior to

manufacture our engineers and local distributors formed teams to visit suppliers and to help

them achieve Toyota quality. I am quite sure they offer a level of quality equivalent to those

manufactured at a Toyota plant in Japan.”

Under the key words ‘Global Best’ the latest generation Toyota Hilux reflects the recent trends

in the worldwide pick-up market. The �007 Hilux answers the needs of world markets with

enhanced performance, advanced technology for off-road driving and premium quality interior

for refinement and comfort.


4� 4�


Sourced from South Africa

• Toyota South Africa Motors is integrated into Toyota supply chain

• Production capacity increased

• High levels of local procurement

• Trade relationship between South Africa and the EU

Toyota South Africa Motors

For European markets, Toyota takes production of the Hilux Single Cab and Double Cab from

Toyota South Africa Motors (TSAM) while the Extra Cab is sourced from Thailand. Global co-

operation on high quality engineering standards and increased investment in production at TSAM

means European sales targets for �007 are being increased to meet demand.

“For Toyota South Africa the IMV project marks the full integration of the company into the Toyota

global supply chain,” says Johan van Zyl, TSAM President and CEO. “The important aspect of this

programme for us is the fact that South Africa is the production base for Europe.

“With that goes an enormous quality responsibility as the expectations in that market are

particularly high. Our IMV programme with the Hilux as the main model fully meets global

expectations and qualifies for the global ‘Built by Toyota’ label.

“The success of the IMV platform since its introduction with production from Thailand in �004

has led to an increase in global volume forecasts by Toyota Motor Corporation in Japan and in line

with this we have increased our production capacity for the IMV now to ��0,000 units a year for

�007.” On top of TSAM’s €�00 million investment in IMV, a brand-new €�06 million paint shop

was opened in September �006, key to increasing the IMV production output.”

For the first time water based technology is introduced in the paint process by TSAM which has

a positive impact on the environment. By using the water based paint process VOC (Volatile

Organic Compound) emissions are reduced from 80 g to �0 g per m� – a reduction of more

than 500 g per vehicle painted. Also the residuals from the paint process can at a high level be

organically absorbed and do not create deposit waste.

The IMV project concept results in more affordable and more attractive vehicles for Toyota

customers while, at the same time, bringing industrial and economic benefits to the host

countries. For instance, procurement rates outside of Japan for IMV projects currently vary

between ��% and �6% and Toyota Motor Corporation’s ultimate target is to achieve �00%.

Within the global IMV scope Toyota South Africa Motors was strategically chosen as the main Hilux

manufacturing base for Europe. The Agreement on Trade, Development & Cooperation (TDCA) from

�� between the South Africa and EU caters for a wide range of trade in commodities and products,

including the motor industry. The agreement both facilitates the procurement of local content and

boosts the trade relationship between the EU and South Africa. Furthermore, vehicles can be exported

or imported under preferential conditions.

Toyota is the first original equipment manufacturer from South Africa to manufacture and export

under the agreement. By having applied the agreement, Toyota is actively supporting local South

African businesses which today supply the majority of the parts and materials used for the Hilux, The

agreement fully complies with the goals of the IMV program which aims at building a local supplier

base.


44 45


Specifications and Equipment Table

46 47

www.toyota-media.comSpecifications 2.5L D-4D 120

Engine 2.5L D-4D 120

Engine code �KD-FTV

Type 4 in-line cylinders

Fuel type 48 Cetane diesel

Valve mechanism DOHC �6-valve

Exhaust system Turbo charger

Intake system Intercooler/Swirl control valve

Displacement (cm�) �,4�4

Bore x stroke (mm) ��.0 x ��.8

Compression ratio ( :�) �7.4

Max. power (kW) DIN hp/rpm (88) ��0/�,600

Max. torque (Nm/rpm) ��5/�,000

Transmission

Type 4x� 4x4

Clutch type Dry, single plate Dry, single plate

Gearbox type 5 M/T 5 M/T

Gear ratios �st 4.�� 4.��

�nd �.��0 �.��0

�rd �.4�6 �.4�6

4th �.000 �.000

5th 0.8�8 0.8�8

Reverse 4.��0 4.��0

Differential gear ratio (front/rear) - / �.58� �.�0� / �.�0�

Brakes 4x2 4x4

Body Type Extra Cab Single/Double Cab Extra Cab

Front Ventilated discs

(Ø�57x�8 mm)

Ventilated discs

(Ø�55x�8 mm)

Ventilated discs

(Ø�55x�5 mm)

Rear Drums (Ø�54 mm) Drums (Ø�54 mm) Drums (Ø��5 mm)

Additional features ABS (optional on Single Cab, base specification)

LSP&BV (Load Sensing Proportioning & Bypass Valve)

Steering

Type Rack and pinion

Ratio (:�) �8.� (4x�), ��.4 (4x4)

Turns (lock to lock) �.8� (4x�), �.7� (4x4)

Min. turning radius – tyre (m) 5.� (4x�), 6.� (4x4)

Additional features Hydraulic Power Steering (HPS)

Off-road performance 4x4

Bodytype Single Cab Extra Cab Double Cab

Min. running ground clearance (mm) ��

Approach angle (°) �0 �0 �0

Departure angle (°) �6 �6 �6

Ramp break over angle (°) �5 �5 �5

Exterior dimensions Single Cab Extra Cab Double Cab

Overall length (mm) 5,�55 5,�55 5,�55

Overall width (mm) �,760 (�,8�5*) �,760 (�,8�5*) �,760 (�,8�5*)

Overall height (mm) �,680 (4x4: �,7�5) �,680 (4x4: �,7�5) �,6�5 (4x4: �,8�0)

Wheelbase (mm) �,085 �,085 �,085

Tread (mm) front �,5�0 (�,540*) �,5�0 (�,540*) �,5�0 (�,540*)

Tread (mm) rear �,5�0 (�,540*) �,5�0 (�,540*) �,5�0 (�,540*)

Overhang (mm) front 885 885 885

Overhang (mm) rear �,�85 �,�85 �,�85

* With over fender

Interior dimensions Single Cab Extra Cab Double Cab

Interior length (mm) �,�40 �,840 �,��0

Interior width (mm) �,475 �,475 �,475

Interior height (mm) �,��0 �,��0 �,��5

Deck space Single Cab Extra Cab Double Cab

Deck floor to ground (mm) 745 (4x4: 860) 750 (4x4: 855) 7�0 (4x4: 850)

Height (mm) 450 450 450

Length (mm) �,��5 �,805 �,5�0

Width (mm) �,5�0 �,5�5 �,5�5

Volume (m�) �,5�0 �,�78 0,�8�

Weights Single Cab Extra Cab Double Cab

Transmission 4x� 4x4 4x� 4x4 4x� 4x4

Kerb weight (kg) �,545-

�,645

�7�0-�805 �585-

�660

�,7�0-

�,8�0

�,6�5-

�,740

�,785-

�,880

Gross vehicle weight (kg) �,7�0-

�,7�5

�,670 �,6�0-

�,700

�,675-

�,685

�,580 �,705-

�,7�5

Towing capacity w/ brakes ��% (kg) �,800 �,�50 �,800 �,�50 �,800 �,�50

Towing capacity w/o brakes (kg) 750 750 750 750 750 750

Max. payload* (kg) �,085-

�,��0

865-�60 �,0�0-

�,��5

855-�45 840-8�5 8�5-��0

* Difference between gross vehicle weight and kerb weight

48 4�

Performance Single Cab Extra Cab Double Cab


Max. speed (km/h) �65 �55 �65 �55 �65 �55

0-�00 km/h (sec.) ��.5 �5.0 ��.5 �5.0 ��.5 �5.�

Fuel consumption

(combined, l/�00km)

7.4 8.� 7.4 8.� 7.5 8.�

Emissions Single Cab Extra Cab Double Cab


CO� (combined, gr/km) * ��7 �� 7 ��

Specifications 3.0L D-4D 170

Engine 3.0L D-4D 170

Engine code �KD-FTV

Type 4 in-line cylinders

Fuel type 48 Cetane diesel

Valve mechanism DOHC �6-valve

Exhaust system Variable Nozzle Turbo charger

Intake system Intercooler/Swirl control valve

Displacement (cm�) �,�8�

Bore x stroke (mm) �6.0 x �0�.0

Compression ratio (:�) �7.�

Max. power (kW) DIN hp/rpm (��6) �7�/�,600

Max. torque (Nm/rpm) �4�/�,400 - �,400

Transmission

Gearbox Type 5 M/T 4 A/T

Clutch type Dry, single plate -

Gear ratios �st 4.�� .804

�nd �.��0 �.5��

�rd �.4�6 �.000

4th �.000 0.705

5th 0.8�8 -

Reverse 4.��0 �.��

Off-road performance 4 X 4

Bodytype Double Cab

Min. running ground clearance (mm) ��

Approach angle (°) �0

Departure angle (°) �6

Ramp break over angle (°) �5

Exterior dimensions Double Cab

Overall length (mm) 5,�55

Overall width (mm) (�,8�5*)

Overall height (mm) (4x4: �,8�0)

Wheelbase (mm) �,085

Tread (mm) front (�,540*)

Tread (mm) rear (�,540*)

Overhang (mm) front 885

Overhang (mm) rear �,�85

* With over fender

Interior dimensions Double Cab

Interior length (mm) �,��0

Interior width (mm) �,475

Interior height (mm) �,��5

Deck space Double Cab

Deck floor to ground (mm) (4x4: 850)

Height (mm) 450

Length (mm) �,5�0

Width (mm) �,5�5

Volume (m�) 0,�8�

Weights Double Cab

Kerb weight (kg) �,840-�,8�0

Gross vehicle weight (kg) �,7�5-�,740

Towing capacity w/ brakes ��% (kg) �,�50

Towing capacity w/o brakes (kg) 750

Max. payload* (kg) 850-8�5

* difference between gross vehicle weight and kerb weight

Performance Double Cab

Transmission 5 M/T 4 A/T

Max. speed (km/h) �70 �75

0-�00 km/h (sec.) ��.0 ��.�

Fuel consumption (combined, l/�00km) * 8.� �.4

Emissions Double CabTransmission 5 M/T 4 A/T

CO� (combined, gr/km) * �� 46

* According to the base directive 80/��68/EEC, latest ammendment �004/�/EC

50 5�

Equipment Table

Single Cab Extra Cab Double Cab4x� DLX

4x4 DLX

4x� DLX

4x4 DLX

4x4 SR

4x4 DLX

4x4 SR 4x4 �.0-litre SR

4x4 �.0- litre SR-X

Exterior

Monotone body colour • • • • • • • • •

Front bumper: material colour • • – – – – – – –

Front bumper: colour-keyed – – • • • • • • •

Rear bumper: grey steel painted • • • • – • – – –

Rear bumper: chrome plated – ° – ° • ° • • •

Chrome side bars – – – – – – – – •

Side steps – – – – • – • • –

Radiator grille: material colour • • • • – • – – –

Radiator grille: colour-keyed

& chrome plated moulding

– – – – • – • • •

�5” steel wheels • – • – – – – – –

�5” steel wheels (w/ center ornamant) – ° – ° – ° – – –

�6” steel wheels (w/ center ornamant) – • – • – • – – –

�5” alloy wheels – – – – • – • • –

�6” alloy wheels – – – – – – – – •

Overfenders: colour-keyed – ° – ° • ° • • •

Front and rear mud guards • • • • • • • • •

Door handles: black • • • • – • – – –

Door handles: chrome – – – – • – • • •

Door mirrors: black • • • • – • – – –

Door mirrors: chrome and electric – – – – • – • • •

Deck guard frame with stopper • • • • – • – – –

Interior

Manual air conditioning ° ° ° ° • ° • • •

Steering column with manual tilt • • • • • • • • •

Power steering • • • • • • • • •

4-spoke steering wheel • • • • • • • • •

Matt paint insert on centre cluster • • • • – • – – –

Silver painted insert on centre cluster – – – – • – • • •

Power door lock ° ° ° ° • ° • • •

Wireless door lock ° ° ° ° • ° • • •

Power window with auto down at: D ° ° ° ° • ° • • •

Rear window defogger – – • • • • • • •

In time adjust & mist wipers • • • • • • • • •

Assist grips • • • • • • • • •

Front door armrest • • • • • • • • •

Front door pocket • • • • • • • • •

Console box with lid ° ° • • • – – –

Console box with lid & rear cup holder – – – – – • • • –

Tachometer • • • • • • • • •

Clock • • • • • • • • •

Optitron metres – – – – – – – • •

Multi-information display – – – – – – – • •

Leather steering wheel – – – – – – – – •

Leather shift knob – – – – – – – – •

Cruise control (only with

automatic transmission)

– – – – – – – • •

Audio

Antenna • • • • • • • • •

� speaker audioless • • • • – • – • •

4 speakers audioless – – ° ° – ° –

�-DIN radio with CD, MP� player,

�60 watt amplifier

° ° ° ° • ° • • –

Full map DVD navigation with NACD/CD – – – – – – – – •

4x4 Technology

Rear differential • • • • • • • • •

Auto disconnect differential – ° – ° • ° • • •

LSD (Limited slip differential)* • • • • • • • • •

Rear diff lock – ° – ° ° ° ° – –

4WD transfer lever & knob – • – • • • • • •

* Depending on market

Single Cab Extra Cab Double Cab4x� DLX

4x4 DLX

4x� DLX

4x4 DLX

4x4 SR

4x4 DLX

4x4 SR 4x4 �.0-litre SR

4x4 �.0- litre SR-X

5� 5�


Safety

ABS ° • ° • • • • • •

SRS airbags (w/o cut off switch): D&P • • • • • • • • •

Front seat belts with �-point ELR,

pretentioners and force-limiters

• • • • • • • • •

Rear seat belts with with � point ELR – – • • • – – – –

Rear seat belts with with � point ELR,

�-point NR

– – – – – • • • •

Collapsible steering column • • • • • • • • •

Headlamp levelling device • • • • • • • • •

Security

Immobilizer • • • • • • • • •

Immobilizer & Pre-Wire for TVSS (RHD only) • • • • – • • • •

Seats

Front seats with vinyl • • – – – – – – –

Front seat 40/60 bench (� persons) • • – – – – – – –

Front seat separate walk-in: P – – • • • – – – –

Front separate seats ° ° – – – • • • •

Rear seat with tip-up function – – – – – • • • •

Seat material: semi low grey fabric ° ° • • – • – – –

Seat material: full high grey fabric – – – – • – • • –

Leather upholstery – – – – – – – – •

• = standards

° = optional

– = not available


54 55


An active investor in South Africa


56 57


An active investor in South Africa• First sold in South Africa in ��6�

• Market leader in cars, light commercials and trucks

• Now building more than ��5,000 vehicles a year, including IMV

As an active investor in the country since ��6�, Toyota has played a key role in the commercial and

social development of modern South Africa. During that time South Africa has emerged not only as

one of Toyota’s major global markets, it has also become home to one of Toyota’s most successful,

high quality manufacturing plants.

The commercial success of Toyota South Africa Motors (TSAM), and the popularity of the Toyota

Hilux in the national market - it is the second most popular Toyota in the country after the Corolla -

made TSAM a natural choice for one of the five global manufacturing facilities for the IMV project.

The introduction of the new Toyota Hilux has redefined manufacturing standards at TSAM as the

company has become fully absorbed into the Toyota Motor Corporation global supply network.

For the first time ever vehicle production for export will exceed production for the local market,

with IMV targeted at 86,000 units in �006, of which 4�,000 will be for export. The annual IMV

production target for �007 is set at ��0.000 units.

This production rate is a far cry from ��6� when �0 Toyopet Stout ‘bakkies’ were imported to the

country from Japan and put on sale. But success, and growth, was rapid. Local assembly started in

��66 and, by ��68, Toyota was the largest producer of commercial vehicles in South Africa.

The milestones of sales success followed. By ��80 Toyota had become market leader in commercial

vehicles and total vehicle sales in South Africa. In ��8�, the year the �00,000th locally produced

Toyota Corolla was built, Toyota topped the passenger car sales charts too.

In ��7�, Toyota took over ownership of Motor Assemblies – the local manufacturing and assembly

company. Further investment followed in ��85 with a local research and development centre at

Eston – the first in South Africa by a motor manufacturer.

The TSAM proving ground in Eston played an essential role in the design and development of the

new Hilux within the IMV project. Although a refined vehicle, the new Hilux needed to retain its

traditional durability, so to survive the most extreme conditions found around the globe. The IMV

development test programme covered a durability test in South Africa by TSAM, also including a

high-altitude drive at �800 m.

In �004, Toyota celebrated �5 years of market leadership for total vehicle sales. One year later,

the IMV production started with production exceeding 86,000 vehicles in �006. To date, more

than two million vehicles have been built at the Prospecton plant, near Durban where recent

investment in the IMV project has passed the €�00 million mark.

In �005 the Hilux production began at TSAM with overall sales over expectations shortly after.

Annual production of all vehicles at TSAM hit a record mark of ��5,�� units. One year later

in �006, the opening of the new paint shop was the key to increasing the capacity of the

production for all IMV-vehicles. The success of the IMV project means more than ��0,000 IMV

vehicles will be built by TSAM in �007 and create many new jobs for the region. TSAM as a whole

employs almost �,500 people today across a wide range of manufacturing, marketing and local

research and development.

In a modern, vibrant local economy, Toyota South Africa Motors has a clear vision of prosperity

for all stakeholders through world competitiveness and continuous growth.

“The rainbow nation”

• A diverse and beautiful country

• Excellent infrastructure and economy

• Hugely varied culture and wildlife

The Republic of South Africa is a diverse and incredibly beautiful country. The size of France and

Spain combined, it covers more than �.� million square kilometres, has a population of around

46 million people and eleven official languages.

South Africa has been described as a cultural melting pot of the African continent and it was

Archbishop Desmond Tutu who coined the phrase ‘the rainbow nation’. The country’s majority

group are Africans (80% of the population); whites make up �%. Descendents of white settlers,

slaves and Africans make up close to �%. Indians comprising about �% of the population, most

of whom live in the province of Kwazulu-Natal, came to South Africa at the beginning of the

twentieth century as indentured labourers.

The country has the most advanced economy in Africa with well-developed mining,

manufacturing, agricultural and financial sectors. It also has an excellent infrastructure with

good air links, road and transport networks. This makes travelling in South Africa on business or

pleasure relatively easy.


58 5�


Politically, South Africa is now a multi-party democracy with President Thabo Mbeki as head of

state. Although the country has a long history of elections, it was not until ��4 that the vast

majority of black South Africans were enfranchised with the ending of apartheid. The African

National Congress is the dominant political party with almost 70% of the vote in the �004 general

election.

The cultural diversity of South Africa also reflects its geography. With a coastline that stretches

almost �,500 km and borders two oceans, the country boasts a great variety of climate zones.

The extreme southwest, the Western Cape, has a climate remarkably similar to that of the

Mediterranean with wet winters and hot, dry summers. This area also produces much of South

Africa’s wine.

Further east on the country’s south coast, rainfall is distributed more evenly throughout the year,

producing a green landscape while the interior is mountainous and sparsely populated with the

northwest dominated by the vast Kalahari desert. A temperature of 5�.7 °C was recorded in ��48

in the Northern Cape Kalahari.

On the north-east coast, the province of Kwazulu-Natal is home to Toyota SA Manufacturing

with its modern plant at Prospecton. With its sub-tropical coastline, thriving commercial centre of

Durban, superb wildlife reserves and diverse ethnic mix, Kwazulu-Natal is a microcosm of South

Africa as a whole.

Durban is the commercial hub of Kwazulu-Natal and developed around its harbour which is now

the largest port in Africa. British in origin, Durban is now truly multi-cultural with a strong Indian

population and is reputedly the fastest growing city in the southern hemisphere.

North and south of Durban lie the long strands of beaches which have made the region a popular

holiday destination while inland are rolling hills and plains made famous by the bloody battles of

the Boer and Zulu wars. To the northeast of the province is the Elephant Coast, home to some

of Africa’s most fascinating wildlife and best game parks – the Hluhluwe-Imfolozi Park and the St

Lucia Wetlands.

It is here that the Hilux Kwazulu-Natal Raid takes place.


60 6�


Welcome to the �007 Hilux press launch during which you will experience the new and powerful

Hilux in the breathtaking splendour of South Africa.

An amazing diversity of animals roams this part of the world, one of them the African Buffalo.

This very powerful and courageous creature, demands respect from even a pride of lions when

paths cross. The African Buffalo as well as the �007 Hilux, truly embody toughness and strength.

Therefore, no other creature than the African Buffalo can better symbolize the Hilux Kwazulu-

Natal Raid.



6� 6�


Toyota Hilux Kwazulu-Natal RaidDay 1Toyota SA Manufacturing – Zimbali Lodgeby luxury coach

• 12.00 – 14.00 Arrival Airport Durban, South Africa from Johannesburg

Coach transfer to TSAM plant

• 14:00 – 14.30 Light lunch at TSAM – Communication Centre

• 14:30 – 15.30 Plant tour

• 15:30 – 16.30 Pan-European Presentations at the TSAM Communication Centre

• 16:30 – 17.30 Coach transfer to Zimbali Lodge

• 17.30 – 18.30 Arrival in Zimbali Lodge and check-in

• 18:30 Cocktails and dinner

TSAM factory visit and press presentations, Prospecton, DurbanHome to Toyota in South Africa, the Prospecton plant opened in ��7� and is the local

manufacturing facility for the Toyota Corolla and the new Toyota Hilux and one of five plants

chosen globally for the IMV project.

In �005, TSAM built a record ��5,�� vehicles, more than one-in-four of South Africa’s total

production of passenger cars and light commercial vehicles. The target is to transform TSAM into

a rationalised and globally efficient two platform manufacturing facility with an annual capacity of

over �00,000 units a year within the next two years.

Total investment in the IMV project at TSAM has topped €406 million including the new

paintshop. The IMV project has created more than 800 additional jobs. Total workforce at TSAM is

now approximately �,500.

Zimbali LodgeThe Zimbali Lodge is a five-star boutique hotel inside the Zimbali Estate, a �70 hectare tropical

coastal residential and resort estate located on the north coast of Kwazulu-Natal and bordering on

the south of the popular holiday destination of Ballito.

The Zimbali Lodge hotel overlooks the Indian Ocean and is decorated to complement the natural

surrounding forest and has several natural spring water lakes which create a beautiful habitat

for the 85 species of bird, hosts of butterflies and a wide variety of indigenous plant life. Animal

life within the forest reserve includes bush buck, blue duiker, bushbaby, vervet monkey, banded

mongoose and even wild pig.


64 65


Day 2Zimbali Lodge – ZululandDriving time: 6 hrsDriving distance: 322 km

• 08:00 – 09.00 Breakfast at Zimbali Lodge

• 09:00 – 09.30 Drive and activity briefing

• 09:30 – 11.30 Test drive from Zimbali Lodge to Hluhluwe Park (Nyalazi Gate)

• 11:30 – 13.00 Briefing and drive through the game reserve

• 13.00 – 14.00 Lunch at Hilltop Restaurant

• 14:00 – 15.00 Continue drive through game reserve to memorial gate to exit park

• 15:00 – 17.00 Cultural drive route drive from Hluhluwe Park to Zululand Rhino Reserve

• 17:00 – 19.00 Arrive at Zululand Rhino Reserve and escorted to Safari Camp

• 19:00 – 19.30 Cultural activity during Cocktails

• 19:30 Dinner at camp

Hluhluwe-Imfolozi ParkThe Hluhluwe-Imfolozi (you pronounce it: ‘shla-shloo-wee oom-fa-low-zee’) is one of South Africa’s

most outstanding game reserves and is considered by some to be better than the Kruger. It is

relatively compact, at �60 square kilometres and was originally two distinct areas, now separated

only by a public road through the middle.

The park is notable for its lack of fencing with the wild animals free to wander at will. The north,

Hluhluwe section, is more rugged and mountainous with forests and grasslands, while the south

and west, the Imfolozi, is more undulating with open savannah.

The park contains an immense diversity of fauna and flora and is particularly famous for its

conservation of black and white rhino. It contains hundreds of endangered black rhino and the

largest population of white rhino in the world.

Hilltop Restaurant - Lunch

The award-winning Hilltop Camp on the summit of a forested hill offers fine views of the

surrounding countryside.

Safari CampOvernight at the Safari camp, set up in the Zebra Hills property in Zululand Rhino Reserve

exclusively for this event. The Reserve is a �800 hectare game reserve in the heart of our rugged

African bush.

The Zululand Rhino Reserve are home to many different species of game, namely, such as black

and white rhino, elephant, buffalo, leopard, spotted hyena, giraffe, zebra, wildebeest, nyala, kudu

and impala. The lion will be introduced in the very near future.

You will enjoy the sights and sounds of South Africa while sleeping out under canvas in

considerable luxury and experience cultural activity over cocktails and a splendid Safari dinner.


66 67


Day 3Driving within Zululand Rhino ReserveDriving time: 5.5 hrsDriving distance: 62 km off-road

• 6:00 – 7.00 Optional Early Morning Game Drive

• 7:00 – 9.00 Breakfast at leisure

• 9:00 – 13.00 Off-road test drive to Nthuli Reserve

• 13:00 – 14.00 Lunch in Nthuli Reserve

• 14:00 – 17.00 Option 1: Advance Technical Drive (max �0 cars)

Option 2: Cultural drive route with assistance of local guides

Option 3: Educational game walk

• 17.00 – 19.00 Return to Safari Camp, time at own disposal

• 19:00 – 19.30 Dinner at camp

Game Drive (optional)The Zululand area is world renowned for its success in re-establishing the white rhino population

and getting it removed from the endangered species list. Today the park is home to around �,600

white rhino and �70 black rhino. It also contains the rest of the Big Five; buffalo, elephant, lion and

leopard, as well as many other species including blue wildebeest, zebra, giraffe, waterbuck, nyala,

kudu, bushbuck, warthog, cheetah, hyena and jackal plus about �4,000 impala.

In excess of �00 species of birds have been recorded including a dozen species of eagle, hawks,

goshawks and honey buzzards. There are around 60 species of reptiles including crocodiles, snakes

and monitor lizards.

Zululand Rhino Reserve, WWF ReserveThe Zululand Rhino Reserve is a �7,000 hectare area in northern Kwazulu-Natal consisting of ��

adjoining properties which have dropped their internal fences in order to create a haven for a

significant black rhino population. The Reserve was chosen as a release site for black rhino with ��

black rhino being released into their new home in �005. The reserve aims at saving endangered

spaces for endangered species, especially the black rhino. The Zululand Rhino Reserve is actively

supported by the WWF and plays an integral role in the WWF Black Rhino Range Expansion

project.

The black rhino, which used to be the most numerous rhino species in the world, became critically

endangered following poaching which wiped out �6% of Africa’s wild black rhino population

in just �0 years. At the lowest point, there were just �,500 black rhino left. Thanks to intensive

protection efforts that number has gradually increased to around �,600.

Everyone who wishes to support the Zululand Rhino Reserve and help prevent the Black Rhino’s

extinction is encouraged to participate in the ‘Adopt a Rhino Program’ for just a small annual fee.

Since there are only �� of these very endangered species this opportunity is an exclusive way of

becoming intimately involved in their conservation.

For more information, please contact the Zululand Rhino Reserve at office@zululandrhinoreserve.

co.za.


68 6�


Day 4Safari Camp – St Lucia EstuaryDriving time: 2.5 hrsDriving distance: 124 km

• 6:00 – 7.00 Optional Early Morning Game Drive

• 7:00 – 9.00 Breakfast, day’s briefing

• 9:00 – 13.00 Test Drive to St Lucia Estuary (World Heritage Site)

• 13:00 – 14.00 Boat trip with lunch

• 14.00 Return to Johannesburg for flights to Europe

Option 1: Coach transfer to Richard’s Bay Airport (� hr)

�5:50 SA�606 flight to JNB

Option 2: Coach transfer to Zimbali Lodge (�hr)

Coach transfer to Durban Airport (�hr)

Flight to JNB

St Lucia EstuaryThe town of St Lucia at the southern end of the St Lucia Wetland Park (a World Heritage Site)

was established by the Portuguese explorer, Manuel Peresterello in �575. A narrow, seven-mile

long tidal channel, the largest estuary in Africa, connects the main body of St. Lucia Lake with the

western Indian Ocean.

The region contains the highest forested dunes in the world, extensive and diverse wetland

systems, as well as coastal grasslands with an associated fauna which includes Africa’s highest

density of common reedbuck. Numerous waterfowl, grassland, forest and sea birds provide an

attraction to birdwatchers from around the world.

Departure to airport

Survival language kit in ZuluGood Day - sawubona / sanibona

Good Morning - as above

Good Afternoon - as above

Good Evening - as above

Good Night - ulale kahle / nilale kahle

Good Bye - usale kahle / nisale kahle (the one leaving says - usale kahle - the other uhambe kahle)

Excuse me - uxolo

Can you help me ? - ngicela ungisize. or ungangisiza?

How are you ? - unjani or kunjani

I’m fine, Thank you - ngiyaphila, ngiyabonga

Nice to meet you - ngiyajabula ukukubona or ngiyajabula ukukwazi

Where is the toilet ? - ingakuphi indlu encane?

Could you wake me up at ... ? - ungangivusa ngo...?

Could I have a warm shower ? - ngingawathola amanzi ashisayo okugeza?

Help ! - Sisani!

Yes - yebo

No - cha

Okay - kulungile

Please - ngiyacela

Very Good - kuhle kakhulu

Thank you - ngiyabonga

Water - amanzi

Wine - iwayini

Beer - ubhiya

No Alcohol for me please - ngiyabonga angiphuzi utshwala

How much is this ? - kuyimalini lokhu?

Tourism destination - indawo yokuvasha

Holiday - isikhathi sekhefu

Visit - vakasha

Come in - ngena

Please pay - ngicela ukhokhe

Where do you come from? - uvela kuphi? or usuka kuyiphi indawo?

We welcome you - siyakwamukela / siyanamukela

How is our service? - Ibenjani impatho yethu

70 7�


New TSAM paint plant Toyota South Africa press releases

Toyota South Africa commissions world class paint plant

Toyota South Africa has commissioned a world class paint plant to replace an existing facility

that could no longer cope with the demand for increased production output for exports and a

rapidly growing domestic market. This latest technology, high efficiency paint plant, located at

Prospecton, near Durban, is one of five similar facilities commissioned by Toyota for its global

operations.

“This latest generation paint plant brings Toyota South Africa right to the forefront of Toyota Motor

Corporation’s vehicle paint technology,” says Toyota South Africa’s President and CEO, Dr. Johan

van Zyl. “The South African plant has adopted the same advanced paint technology used In TMC’s

nine paint plants in Japan. One of the major features of this system is its ability to use metallic

water-borne paint for the top coat, which greatly reduces emissions“.

“This new paint facility is key to the expansion of the Prospecton manufacturing plant to a planned

production capacity of ��0 000 units per annum. Daily production volumes to achieve that level

will be realised during �008. The first full year of production at the ��0 000 unit level will be �00�.

At that time we anticipate that Toyota South Africa will be exporting approximately half of its

production as a fully integrated element of the TMC global vehicle supply chain“.

“The new paint facility represents an investment of more than R�-billion and is a major part of our

��0K production programme which has seen Toyota South Africa commit to a multi-million Rand

investment in tooling and facilities over the past three years. This investment includes an amount

of R�,4-billion spent in gearing up for the IMV (Innovative International Multi-purpose Vehicle)

project, which was the first high volume export project for Toyota South Africa“.

“Historically the paint process has been an impediment to increasing production at Prospecton.

In recent months this inability to fully supply customer demand in a booming local market has

created a backlog for certain models. This new paint plant, with its design capacity of ��0 000

units per annum, replaces facilities that imposed a volume constraint of a maximum of ��0 000

units per annum“.

“During the construction of the new plant even more severe production constraints have been in

place as the new plant has been erected on the site of one of our former paint plants. This meant

we had only one operational paint shop for many months. However, these constraints will ease

during October as the new facility comes fully on line for our Hilux and Fortuner production.

Production will then go up by �0% from 600 to 7�0 units per day. This will assist us to regain

market share lost during the construction of the new paint facility“.

“The transition to environmentally-friendly water borne paint technology will see our current VOC

(Volatile Organic Compound) emissions reduce from 80gm per m� to just �0 gm per m� painted,

a figure that conforms fully with international standards. This will contribute to an 60% reduction

in the air emissions from the new plant, compared to our previous two paint plants, while, at full

capacity, there will also be reduced electricity usage in terms of the cost per unit“.

“Traditionally propane has been used to fire the paint shop ovens. The new facility has been

designed to run on methane-rich natural gas, a product of the Mozambique gas fields, supplied

by Sasol. This natural product replaces a refined product with significant savings in handling“.

“Aside from the economic and environmental benefits of this new facility there will be a significant

quality benefit as well“.

“This new facility will offer a nominal number of new job opportunities,” commented Dr. van

Zyl. “We have planned for an increase of some 50 personnel in the paint operation. Importantly,

the addition of the new paint plant to our facilities further underlines Toyota’s commitment to

the KwaZulu-Natal region. As such it will add a high level of economic stability to the Prospecton

area as Toyota advances towards its target of ��0 000 units per annum production as a large-scale

exporter of world class vehicles. There are also further job opportunities flowing from the suppliers

we are attracting to the region“.

“A huge investment has been made in training the people who work in the new paint plant. A

total of 58 senior team members went to Japan for extensive training over a seven month period,

at a cost of R��-million. A further �50 team members have undergone training locally over a

period of five months“.

“We are very proud of Toyota Motor Corporation’s bold vision for our South African operation,

going into the future. This new paint plant is yet another example of their ongoing commitment

to our country’s economy and to job creation and skills development,” concluded Dr. van Zyl.

Ends

SA Paint Shop

September �006

Appendix


7� 7�


Painting by the numbers – Toyota’s replacement paint shop

The size and scale of Toyota South Africa’s new paint shop dating back to ��7�, is best illustrated

by a brief review of some of the statistics.

• R1- billion - The total cost of the project including site preparation and construction costs

as well as plant and equipment costs amounted to more than R�-billion. Some 50% of

expenditure on plant, machinery, services and civil engineering work was with local companies.

The Black Economic Empowerment (BEE) component was approximately R�50-million.

• 23 000 m2 - the footprint of the facility (equal to 4,5 rugby fields). The total floor area is

4� 000 m� (equal to 8,� rugby fields).

• 2 000 – The number of people that worked on site at various times.

• 60 – The number of contractors involved in the project. 77% had BEE status.

• 220 000 - the unit capacity of the new facility, working two shifts of eight hours each.

• 60% - The reduction in air emissions, especially VOC (Volatile Organic Compound) emissions.

All exhaust gases from the drying ovens and all volatile solvent emissions are processed

through a Regenerative Thermal Oxidiser (RTO) where they are burnt off with the assistance of

a gas burner.

• 60 man months - Overseas training of 58 paint shop personnel at a cost of R��-million.

• 55 metres - The height of the tower cranes used in the construction of the �0 metre high

structure. The facility is situated directly in the flight path for Durban International Airport

and special permission was required from the Department of Civil Aviation to erect the tower

cranes. Radar operators at the airport had to remain aware of the building because the airport

radar picked up the movement of the cranes.

Ends

Painting by the numbers

September �006

A new approach to vehicle painting

Toyota South Africa’s new paint plant, a replacement on the same site for a facility that could no longer

meet demands for increasing production output, boasts the latest efficiencies and technology seen

anywhere in the Toyota production world. The Prospecton facility is one of five similar units built by

Toyota Motor Corporation (TMC) for its expanding global operations.

The new facility replaces a facility known as Paint Plant �, which together with Paint Plant � provided

Toyota South Africa with a realistic maximum capacity of ��0 000 units per year, all painted with solvent-

based technology. Once fully commissioned the new facility will have capacity for ��0 000 units per

annum, using the latest water-borne paint technology. This will make Paint Plant � redundant in the

future, freeing up valuable space on the Prospecton site.

Underbody sealing, previously a messy manual process, is now automated. Non-PVC sealant is used

that offers the advantage of reduced chloride emissions.

Environmentally the introduction of water based technology will have a major impact at Toyota South Africa.

In the water based process the paint is applied as supplied without any additional handling required before

application. By using a water based paint process VOC (Volatile Organic Compound) emissions are reduced

from 80 gm to �0 gm per m� painted - a reduction of more than 500 gm per vehicle painted.

A new system cuts the use of solvent in the flush out process for a colour change. The highly aggressive

solvent used previously is now replaced by a substantially more environmentally friendly flushing medium.

All working decks are fully climate controlled. Positive ventilation, with filtered air, inhibits dust entry

from outside of the facility. Up until now a vehicle body typically arrived in the paint plant on a sled

from the body shop and remained on that sled through to its hand over to the assembly hall. This

created opportunities for the transfer of dirt and dust - the worst impediments to paint quality - into

the paint facility. Now all sleds used in the paint shop are exclusive to this area removing the exposure

to cross contamination between body shop and paint facilities.

In all areas where dust is created by any process, such as the block and polish area, dust traps are

installed to ensure that any opportunity for contamination is limited.

Design detail has focused on reduced emissions, energy savings, and quality improvement throughout

this modern facility. The new facility will significantly enhance quality standards, already at a high level,

and make these high standards more easily sustainable. The incidence of dust imperfections, which is

already low at Toyota’s existing paint plant, is expected to reduce substantially in the new facility.

Ends

New painting

September �006


74 75


New Toyota paint plant – a construction challenge

Toyota’s new paint plant at Prospecton presented a number of construction challenges and the

solutions have made it unique in many ways.

Perhaps the biggest challenge was presented by the aggressive environment in the Durban area

with its highly corrosive atmosphere. This led the design team to implement a unique, all concrete,

structure for the facility.

By using concrete rather that metal cladding as the major construction medium the impact of the

corrosive high humidity and high salt content of the atmosphere in the Durban area is limited.

While this facility is essentially the same as four other paint shops built recently around the world

by Toyota Motor Corporation (TMC), the concrete structure differentiates Toyota South Africa’s

newly erected facility.

The bare structure was completed at a cost of R�80 million, including the cost of clearing the

previous paint shop from the site. Construction started with the demolition of the existing plant

in mid �004. The first piled foundations were placed in November of that year and building of the

structure began in February �005.

There were 60 contractors involved in this project, with 77% of them having BEE status. During

construction a total of � 000 people worked on the building site. Most of the civil engineering

work and services were provided by KwaZulu-Natal based companies, although some resources

came from Johannesburg.

Japanese companies supplied 64% of the specialised equipment, while South African suppliers

contributed �5,5% and Thailand supplied a small amount. The Black Economic Empowerment

(BEE) component of the construction and equipment supply amounted to a substantial R�50-

million.

Construction of the actual building was completed in December �005 and the installation of

equipment began in January �006. Pre-production trials started in late August �006 with the plant

ready for commissioning in September �006 and available for volume production in October �006,

right on schedule.

Ends.

Paint shop construction

September �006

R1- billion paint plant moves toyota sa closer to completion of multi-billion rand investment programme

The commissioning of a new R�-billion paint plant in Prospecton, a replacement for an out of

date facility, during October will move Toyota South Africa closer to the completion of its five year

plant modernisation and expansion programme. The company, 75% owned by Toyota Motor

Corporation Japan, began the programme in anticipation of the production of the new Hilux as an

element of the Toyota global International Innovative Multipurpose Vehicle (IMV) programme.

“Investment in this, the first true high volume export model for Toyota South Africa, was R�,4-

billion,” says Toyota South Africa’s President and CEO, Johan van Zyl. “The successful completion

of this project and the introduction of the IMV resulted in Toyota Motor Corporation (TMC)

giving an emphatic indication of its confidence in Toyota South Africa as a partner in its global

manufacturing network by announcing that the Prospecton plant would become a source plant

for a second high volume export model.

The introduction of the second export model required that the Prospecton facility be expanded

to a volume capacity of ��0 000 units per annum working on a two shift basis. This production

level will be achieved during �008. A new, low emissions water based paint plant was an essential

requirement of the plant expansion to meet production, quality and global environmental

expectations.

Further investment was budgeted for this expansion that will see Toyota South Africa established

as the major exporter of fully built up vehicles from South Africa by �007. The timing for the

completion of the investment programme is the first quarter of �007. The completion of the

��0K programme could create as many as � 000 new job opportunities by �00� as production is

ramped up.

In addition to the R�-billion investment in the new paint plant featuring the latest technology

in the world – it is one of five similar plants commissioned by TMC globally – there is a further

investment in a press shop expansion which will double component stamping capacity with the

addition of a second “A0” press line.

Enhancements in the vehicle assembly hall, body and chassis line, plastic component production

and painting, and tooling up for the new model have been budgeted are also under way.

Approximately 50% of the total investment amount is being spent with local suppliers.


76 77

A further production enhancement is a steel blanking line. This facility is a joint venture between

TTC and Toyota Tsusho Corporation and Toyota Tsusho Africa (TTAF) and will, for the first time, see

Toyota South Africa take delivery of steel for body panels in coil form for on-site processing into cut

sheets for stamping.

Dr. van Zyl concluded by saying “With the completion of all of these projects Toyota South Africa

will lead the way in vehicle production in South Africa as a fully integrated facility within the Toyota

global production network. By �00�, when Toyota South Africa is producing at its full ��0 000

units per annum capacity, approximately half of that production will be for export markets. This

will be a ��0% increase over the 50 000 units due to be exported by Toyota South Africa in �006.”

Ends

Paint shop investment

September �006



78 7�


camioneta hilux

Documents

volatile organic compound

dynamic route guidance

mount upper arm

front fog lamps

center ornamant

deep front bumper

exhaust gas recirculation

johan van zyl