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2007 Toyota Hilux

Dynamic Press Launch, Kwazulu Natal

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The 2007 Toyota Hilux


A true work & leisure vehicle

Powerful new diesel engines Choice of smooth transmissions Legendary off-road performance Evolving to exceed market expectations Toyota IMV: a truly global project Specifications and equipment table An active investor in South Africa Toyota Hilux Kwazulu-Natal Raid Appendix: new TSAM paint plant

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The 007 Toyota Hilux

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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

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.

The 007 Toyota Hilux is launched with a powerful new range of diesel engines and styling enhancements to offer todays 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 Cruisers 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.

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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 Toyotas 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 6,67 units. The Hilux is one of three vehicles being developed under Toyotas IMV (Innovative International Multipurpose 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.

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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 4Nm 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
(Nm) 500 450 400 350 300 250 200 150 (kW) 150 140 130 120 110 100 80 70 60 50 40 30 20 10 500 1000 1500 2000 2500 3000 3500 4000 4500

Engine speed (rpm)





Output

Torque

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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 mixtures 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

Switching valve

EGR gas outlet (bypass side)

EGR gas inlet

EGR gas outlet (cooler side)

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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.

Engine performance curve 2,5 D-4D


(Nm) 350 (kW) 100 90 80 300 70

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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

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150

500 1000 1500 2000 2500 3000 3500 4000 4500

Engine speed (rpm)

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.

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 D4D 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.

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Output

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Torque

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Choice of smooth transmissions

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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 fivespeed manual gearbox on Double Cabs. The option of four-speed automatic transmission on Hilux is a further example of how Toyotas 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 Toyotas 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 Signal AI-SHIFT


Position sensor
Throttle opening angle Vehicle speed Engine speed Brake signal

Road conditions Uphill/Downhill driving


Smaller Estimating grade Greater Greater Criterion acceleration Actual acceleration

Bassic shift pattern control

Road condition support control

Drivers intention Calculated by ECU


Vehicle acceleration Acceleration pedal operation Vehicle condition Estimating drivers intention

Drivers intension support control

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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.





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Legendary off-road performance

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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 todays 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

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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.

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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 offroad 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 Piece Front Drive Clutch Sleeve Front Drive Hub Rear Output Shaft

With the SR and SR-X 4x4 grades comes Toyotas 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 RH propshaft

Transfer Input Shaft


Shift Pattern

Silent Chain

Oil Pump

Front Driven Sprocket

Drive Shaft

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

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.

Panetary Ring Gear Pinion Shaft Transfer Input Shaft Planetary Carrier Planetary Spline Piece Planetary Pinion Gear Planetary Ring Gear Planetary Carrier Planetary Spline Piece High and Low Clutch Sleeve High and Low Clutch Sleeve High and Low Clutch Hub Planetary Sun Gear Planetary Pinion Gear Rear Output Shaft

Transfer Input Shaft

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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

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.

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.

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Evolving to exceed market expectations





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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 ,50 mm for the Double Cab. The Extra Cab load length is ,805 mm.

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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 classleading 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 .0litre 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.

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Toyota IMV: a truly global project

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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 Toyotas 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. Toyotas 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% (FY005) 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 Toyotas 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.

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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

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 TSAMs 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 Corporations 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.

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 cooperation 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.

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Toyota Hilux Kwazulu-Natal Raid

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Specifications and Equipment Table

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Specifications 2.5L D-4D 120


Engine Engine code Type Fuel type Valve mechanism Exhaust system Intake system Displacement (cm) Bore x stroke (mm) Compression ratio ( :) Max. power (kW) DIN hp/rpm Max. torque (Nm/rpm) Transmission Type Clutch type Gearbox type Gear ratios st nd rd 4th 5th Reverse Differential gear ratio (front/rear) Brakes Body Type Front Rear Additional features Extra Cab Ventilated discs (57x8 mm) Drums (54 mm) 4x Dry, single plate 5 M/T 4. .0 .46 .000 0.88 4.0 - / .58 4x2 Single/Double Cab Ventilated discs (55x8 mm) Drums (54 mm) 4x4 Dry, single plate 5 M/T 4. .0 .46 .000 0.88 4.0 .0 / .0 4x4 Extra Cab Ventilated discs (55x5 mm) Drums (5 mm) Weights Transmission Kerb weight (kg) Steering Type Ratio (:) Turns (lock to lock) Min. turning radius tyre (m) Additional features Rack and pinion 8. (4x), .4 (4x4) .8 (4x), .7 (4x4) 5. (4x), 6. (4x4) Hydraulic Power Steering (HPS) Towing capacity w/ brakes % (kg) Towing capacity w/o brakes (kg) Max. payload* (kg) Gross vehicle weight (kg) Single Cab 4x ,545,645 ,70,75 ,800 750 ,085,0
* Difference between gross vehicle weight and kerb weight

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2.5L D-4D 120 KD-FTV 4 in-line cylinders 48 Cetane diesel DOHC 6-valve Turbo charger Intercooler/Swirl control valve ,44 .0 x .8 7.4 (88) 0/,600 5/,000

Off-road performance Bodytype Min. running ground clearance (mm) Approach angle () Departure angle () Ramp break over angle () Exterior dimensions Overall length (mm) Overall width (mm) Overall height (mm) Wheelbase (mm) Tread (mm) front Tread (mm) rear Overhang (mm) front Overhang (mm) rear
* With over fender

4x4 Single Cab  0 6 5 Single Cab 5,55 ,760 (,85*) ,680 (4x4: ,75) ,085 ,50 (,540*) ,50 (,540*) 885 ,85 Extra Cab  0 6 5 Extra Cab 5,55 ,760 (,85*) ,680 (4x4: ,75) ,085 ,50 (,540*) ,50 (,540*) 885 ,85 Double Cab  0 6 5 Double Cab 5,55 ,760 (,85*) ,65 (4x4: ,80) ,085 ,50 (,540*) ,50 (,540*) 885 ,85

Interior dimensions Interior length (mm) Interior width (mm) Interior height (mm) Deck space Deck floor to ground (mm) Height (mm) Length (mm) Width (mm) Volume (m)

Single Cab ,40 ,475 ,0 Single Cab 745 (4x4: 860) 450 ,5 ,50 ,50

Extra Cab ,840 ,475 ,0 Extra Cab 750 (4x4: 855) 450 ,805 ,55 ,78 Extra Cab 4x 585660 ,60,700 ,800 750 ,00,5 4x4 ,70,80 ,675,685 ,50 750 855-45

Double Cab ,0 ,475 ,5 Double Cab 70 (4x4: 850) 450 ,50 ,55 0,8 Double Cab 4x ,65,740 ,580 ,800 750 840-85 4x4 ,785,880 ,705,75 ,50 750 85-0

ABS (optional on Single Cab, base specification) LSP&BV (Load Sensing Proportioning & Bypass Valve)

4x4 70-805 ,670 ,50 750 865-60

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Performance Transmission Max. speed (km/h) 0-00 km/h (sec.) Fuel consumption (combined, l/00km) Emissions Transmission CO (combined, gr/km) *

Single Cab 4x 65 .5 7.4 4x4 55 5.0 8.

Extra Cab 4x 65 .5 7.4 4x4 55 5.0 8.

Double Cab 4x 65 .5 7.5 4x4 55 5. 8.

Exterior dimensions Overall length (mm) Overall width (mm) Overall height (mm) Wheelbase (mm) Tread (mm) front Tread (mm) rear

Double Cab 5,55 (,85*) (4x4: ,80) ,085 (,540*) (,540*) 885 ,85

Single Cab 4x 7 4x4 

Extra Cab 4x 7 4x4 

Double Cab 4x  4x4 

Overhang (mm) front Overhang (mm) rear * With over fender Interior dimensions Interior length (mm) Interior width (mm)

Specifications 3.0L D-4D 170


Engine Engine code Type Fuel type Valve mechanism Exhaust system Intake system Displacement (cm) Bore x stroke (mm) Compression ratio (:) Max. power (kW) DIN hp/rpm Max. torque (Nm/rpm) Transmission Gearbox Type Clutch type Gear ratios st nd rd 4th 5th Reverse Off-road performance Bodytype Min. running ground clearance (mm) Approach angle () Departure angle () Ramp break over angle () 5 M/T Dry, single plate 4. .0 .46 .000 0.88 4.0 4X4 Double Cab  0 6 5 4 A/T .804 .5 .000 0.705 . 3.0L D-4D 170 KD-FTV 4 in-line cylinders 48 Cetane diesel DOHC 6-valve Variable Nozzle Turbo charger Intercooler/Swirl control valve ,8 6.0 x 0.0 7. (6) 7/,600 4/,400 - ,400

Double Cab ,0 ,475 ,5 Double Cab (4x4: 850) 450 ,50 ,55 0,8 Double Cab ,840-,80 ,75-,740 ,50 750 850-85

Interior height (mm) Deck space Deck floor to ground (mm) Height (mm) Length (mm) Width (mm) Volume (m) Weights Kerb weight (kg) Gross vehicle weight (kg) Towing capacity w/ brakes % (kg) Towing capacity w/o brakes (kg) Max. payload* (kg)
* difference between gross vehicle weight and kerb weight

Performance Transmission Max. speed (km/h) 0-00 km/h (sec.) Fuel consumption (combined, l/00km) * 5 M/T 70 .0 8.

Double Cab 4 A/T 75 . .4

Emissions
Transmission CO (combined, gr/km) * 5 M/T 

Double Cab
4 A/T 46

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

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Equipment Table
Single Cab 4x 4x4 DLX DLX 4x DLX Extra Cab 4x4 4x4 DLX SR Double Cab 4x4 4x4 SR 4x4 DLX .0litre SR 4x4 .0litre SR-X 4x4 Technology 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 Rear differential Auto disconnect differential LSD (Limited slip differential)* Rear diff lock 4WD transfer lever & knob
* Depending on market

Single Cab 4x 4x4 DLX DLX

4x DLX

Extra Cab 4x4 4x4 DLX SR

Double Cab 4x4 4x4 SR 4x4 DLX .0litre SR

4x4 .0litre 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 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

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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

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Toyota Hilux Kwazulu-Natal Raid

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An active investor in South Africa

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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 Toyotas major global markets, it has also become home to one of Toyotas 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 countrys 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.

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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 Africas wine. Further east on the countrys 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 Africas 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.

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Toyota Hilux Kwazulu-Natal Raid

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 KwazuluNatal Raid.

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Toyota Hilux Kwazulu-Natal Raid


Day 1
Toyota SA Manufacturing Zimbali Lodge by luxury coach 12.00 14.00 14:00 14.30 14:30 15.30 15:30 16.30 16:30 17.30 17.30 18.30 18:30 Arrival Airport Durban, South Africa from Johannesburg Coach transfer to TSAM plant Light lunch at TSAM Communication Centre Plant tour Pan-European Presentations at the TSAM Communication Centre Coach transfer to Zimbali Lodge Arrival in Zimbali Lodge and check-in Cocktails and dinner

TSAM factory visit and press presentations, Prospecton, Durban Home 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 Africas 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 Lodge The 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.

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Toyota Hilux Kwazulu-Natal Raid

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Day 2
Zimbali Lodge Zululand Driving time: 6 hrs Driving distance: 322 km 08:00 09.00 09:00 09.30 09:30 11.30 11:30 13.00 13.00 14.00 14:00 15.00 15:00 17.00 17:00 19.00 19:00 19.30 19:30 Breakfast at Zimbali Lodge Drive and activity briefing Test drive from Zimbali Lodge to Hluhluwe Park (Nyalazi Gate) Briefing and drive through the game reserve Lunch at Hilltop Restaurant Continue drive through game reserve to memorial gate to exit park Cultural drive route drive from Hluhluwe Park to Zululand Rhino Reserve Arrive at Zululand Rhino Reserve and escorted to Safari Camp Cultural activity during Cocktails Dinner at camp

The award-winning Hilltop Camp on the summit of a forested hill offers fine views of the surrounding countryside. Safari Camp Overnight 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.

Hluhluwe-Imfolozi Park The Hluhluwe-Imfolozi (you pronounce it: shla-shloo-wee oom-fa-low-zee) is one of South Africas 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

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Day 3
Driving within Zululand Rhino Reserve Driving time: 5.5 hrs Driving distance: 62 km off-road 6:00 7.00 7:00 9.00 9:00 13.00 13:00 14.00 14:00 17.00 Optional Early Morning Game Drive Breakfast at leisure Off-road test drive to Nthuli Reserve Lunch in Nthuli Reserve Advance Technical Drive (max 0 cars) Cultural drive route with assistance of local guides Educational game walk Return to Safari Camp, time at own disposal Dinner at camp

Everyone who wishes to support the Zululand Rhino Reserve and help prevent the Black Rhinos 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.

Option 1: Option 2: Option 3:

17.00 19.00 19:00 19.30

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 Reserve The 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 Africas 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.

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Day 4
Safari Camp St Lucia Estuary Driving time: 2.5 hrs Driving distance: 124 km 6:00 7.00 7:00 9.00 9:00 13.00 13:00 14.00 14.00 Option 1: Option 2: Coach transfer to Zimbali Lodge (hr) Coach transfer to Durban Airport (hr) Flight to JNB St Lucia Estuary The 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 Africas highest density of common reedbuck. Numerous waterfowl, grassland, forest and sea birds provide an attraction to birdwatchers from around the world. Departure to airport Optional Early Morning Game Drive Breakfast, days briefing Test Drive to St Lucia Estuary (World Heritage Site) Boat trip with lunch Return to Johannesburg for flights to Europe Coach transfer to Richards Bay Airport ( hr) 5:50 SA606 flight to JNB

Survival language kit in Zulu


Good 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 Im 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

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New TSAM paint plant

we had only one operational paint shop for many months. However, these constraints will ease Toyota South Africa press releases 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 70 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 Toyotas 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 Corporations 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 countrys economy and to job creation and skills development, concluded Dr. van Zyl. Ends SA Paint Shop September 006

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 Corporations vehicle paint technology, says Toyota South Africas President and CEO, Dr. Johan van Zyl. The South African plant has adopted the same advanced paint technology used In TMCs 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

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Painting by the numbers Toyotas replacement paint shop


The size and scale of Toyota South Africas 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 R50-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.

A new approach to vehicle painting


Toyota South Africas 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 solventbased 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 Toyotas existing paint plant, is expected to reduce substantially in the new facility. Ends New painting September 006

Ends Painting by the numbers September 006

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New Toyota paint plant a construction challenge


Toyotas 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 Africas newly erected facility. The bare structure was completed at a cost of R80 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 R50million. 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,4billion, says Toyota South Africas 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.

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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

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