Geneva Motorshow 2005

CORPORATE UPDATE

• Toyota sets European sales target of 980,000 units for 2005
• In 2004, Toyota sold 915,966 vehicles in Europe, an increase of 10% over the previous year
• 582,695 cars, 494,635 engines and 195,163 transmissions produced in Europe
• Yaris, Avensis, RAV4, Corolla Verso and Prius achieve annual sales records
• Production of the new Toyota AYGO to start in Czech Republic this year (100,000 units per year)
• Toyota’s European manufacturing operations are now spread through 6 countries
• J.D. Power surveys and ADAC’s AutoMarxX confirm Toyota’s high customer satisfaction

Toyota has set itself the challenge of selling 980,000 units in Europe in 2005, which represents a sales increase of 7% over the previous year.

Toyota achieved an eighth consecutive record year of sales in Europe in 2004. With 915,966 vehicles delivered – 24,913 Lexus and 891,053 Toyota – the world’s third-largest car manufacturer saw sales rise by 10% over the previous year, in a total market up an estimated 2%. This resulted in a market share of 5% – the highest ever for Toyota in Europe. Toyota also produced 582,695 cars, 494,635 engines and 195,163 transmissions at its plants in the U.K., France, Turkey and Poland.

“Toyota has worked diligently in providing superior quality products, service and value to our customers, and we are eagerly looking forward to building on our eighth consecutive year of record sales,” said Dr. Takis Athanasopoulos, Executive Vice-President of Toyota Motor Europe (TME). “Toyota is also very proud that its hybrid Prius model won the prestigious 2005 European Car of the Year award, as this is another step toward Toyota’s goal of providing sustainable mobility, in line with our vision of ‘Today for Tomorrow’,” Dr. Athanasopoulos concluded.

The Toyota Yaris not only achieved its sixth consecutive year of record sales, but it broke Toyota’s annual record for single model sales (227,517 units, +5%). Toyota Avensis sales also reached an annual record, with 145,111 units sold (+25%). Toyota’s widely-acclaimed RAV4 and legendary Land Cruiser also achieved record sales, with 109,059 units sold (+4%) and 41,874 units sold (+9%) respectively. And in 2004, sales of the Toyota Corolla (excluding the Corolla Verso) reached 185,136 units (+4%), while Corolla Verso sales achieved an annual sales record of 64,249 units sold (48%). Sales of the Toyota Prius jumped 960% to 8,248 units.

The Lexus luxury brand also achieved a new annual sales record, with 24,913 units sold, or 15% higher than last year, thanks to record annual sales of the RX300 luxury SUV (14,137 units, +50%).

The U.K. set a new European sales record (138,097 units, +3%), and was Toyota’s largest market in Europe in 2004. Italy was Toyota’s second-largest market, with an annual sales record of 128,738 units (+3%), while Germany was third-largest (120,353 units, +13%) also setting a new annual sales record. France (80,272 units, +9%) and Spain (56,276 units, +28%) also enjoyed annual sales records and were, respectively, Toyota’s fourth- and fifth-largest markets.

All-time annual sales records were also achieved in Russia (45,907 units, +83%) and Hungary (13,196 units, +9%).

In October 2004, Toyota manufactured its 2.5 millionth vehicle in Europe, achieving a significant milestone in the company’s European manufacturing history. Toyota currently manufactures all of its core models – the Yaris, Avensis, Corolla and Corolla Verso – in Europe, and will have a total maximum production capacity of 675,000 vehicles per year. In addition, Toyota and PSA Peugeot Citroën will start manufacturing 300,000 entry-level small passenger cars in the Czech Republic this year, of which 100,000 will be for the Toyota brand, named the Toyota AYGO.

In 2005, Toyota’s manufacturing operations will count eight manufacturing plants in six different countries (U.K., France, Poland, Turkey, Portugal and the Czech Republic). And Toyota’s sales and marketing operations will also include Turkey in 2005.

High standards of customer satisfaction

• Toyota ranks first in J.D. Power’s German CSI
• Lexus is number one in J.D. Power’s UK CSI
• Second position in Germany’s ADAC AutoMarxX

Toyota’s reputation for superior quality also continued in 2004: Toyota models ranked the highest in three out of seven vehicle segments in J.D. Power’s 2004 Germany Customer Satisfaction Index – with Toyota being ranked the top car brand overall. Lexus achieved the number one position in J.D. Power’s 2004 U.K. Customer Satisfaction Index, while Toyota climbed to second in Germany’s ADAC AutoMarxX December 2004 report – the first non-German manufacturer to achieve such a high position.

THE NEW AYGO BY TOYOTA: URBAN DYNAMISM FOR THE NEW GENERATION

KEY POINTS

• Aygo name symbolises freedom and mobility
• Built in the Czech Republic – 100,000 units a year
• Available in the UK in three grades: T2, T3 and Sport
• Option packs available to enhance specification
• Superior safety package with four airbags standard on T3 and Sport grades and seatbelt warning system fitted to all models
• Strong but lightweight body makes extensive use of high tensile steel
• New 1.0-litre three-cylinder petrol engine
• Most powerful and highest torque producing 1.0-litre unit on the market, also the world’s lightest production car engine
• Class leading fuel consumption and carbon dioxide emissions
• Optional Multi-mode Manual Transmission (MMT)
• Aygo among the cheapest in its class for running and repair costs
• On sale in the UK from 1 July

INTRODUCTION

Aygo is a car which answers all the demands of modern urban living, being highly practical and easy to park while delivering a dynamic driving experience and offering a cool modern design. Measuring 3,405mm long, 1,615mm wide and 1,465mm tall, it is the smallest car Toyota has marketed in Europe.

The name Aygo, pronounced eye-go, expresses freedom and mobility – just what the car will offer to its target market of urban men and women with active lifestyles. In short, Aygo is about easy but dynamic urban mobility.

Aygo marks a new approach for Toyota in several aspects. It has the potential to attract customers younger than the average Toyota driver: Toyota expects 80 to 90 per cent of Aygo owners to be new to the brand.

“We see a very positive mutual relationship between Aygo and the Toyota brand,” said Andrea Formica, Toyota Europe Vice-President of Sales and Marketing. “Aygo brings emotional attributes to Toyota’s rational values of superior quality, durability and reliability. The ‘Aygo by Toyota’ logo featured at the Toyota stand (at the Geneva Motor Show) and due to be used at dealerships throughout Europe visualises this powerful combination.

“Furthermore, we have taken a unique approach to the Toyota Aygo’s launch process and lifecycle management, different from any used for any other Toyota model before. The Aygo launch campaign will target several major European cities, rather than focusing on countries. Toyota also intends, through several initiatives, to keep the Aygo fashionable throughout its lifespan.”

In total, 100,000 Aygo models will be produced each year in the Czech Republic.

A NEW DESIGN PHILOSOPHY

Aygo’s styling expresses Vibrant Clarity, a new Toyota design philosophy.

“Japanese culture, or what we like to call the ‘J-factor’, forms the foundation for Toyota’s unique design direction, Vibrant Clarity,” said Wahei Hirai, Managing Officer of the Toyota Design Centre.

Aygo disproves the view that small cars are purely about economy by focusing on the fun and enjoyment compact vehicles can deliver. The body has a low line that emphasises the wheel flares; shortened overhangs and a cab-forward design help achieve a roomy interior within an overall compact exterior.

The front end design displays the new face of Toyota, with a strong three-dimensional form that flows from the Toyota badge.

The interior is in the same spirit as the exterior with a compact instrument panel with a two-tone finish. The car’s character is further expressed in the cylinder-shaped heated control unit and the simple, modern graphics used on the meters.

The door trim carries over the exterior body colour to give the cabin a sporty feel that’s also shown in the design of the steering wheel and gear lever. The adjustable steering column and principle meters form a single unit, which means the dials remain in clear view.

Toyota has used a new graining finish on the dashboard that is not only more attractive but which also sets new standards for scratch resistance, ease of cleaning and resistance to ageing.

The modern, clean design of the seats creates a figure-hugging effect, and the upholstery is both highly durable and of excellent quality.

INTERIOR AND PRACTICALITY

Aygo’s interior was developed to accommodate passengers of all sizes, including very tall people. Achieving a large amount of usable interior space has been helped by the car having particularly short front and rear overhangs. Passenger comfort is heightened thanks to one of the most generous measurements between front and rear hip points of any A segment car.

The cabin features plenty of handy storage spaces, including four door pockets, eight trays, three cup holders, a coin case and large vanity mirrors.

THERE’S AN AYGO FOR EVERYONE

In the UK the Aygo will be offered in three grades: T2, T3 and Sport. All come with a generous range of equipment as standard and can be enhanced with a wide choice of options.

T2 versions of the car are equipped with ABS and EBD, colour keyed bumpers, driver and front passenger airbags, power steering, a heated rear window with wiper and two-speaker audio system with radio and CD player.

The T3 model introduces colour keyed door mirrors and handles, electric front windows, a 50:50 split-folding rear seat, remote central locking, rear headrests, ISOFIX child seat anchor points and an upgraded sound system with two rear speakers and front tweeter speakers.

The Sport adds more street style to the package with five-spoke alloy wheels, front fog lamps and a tachometer. Air conditioning and metallic paint are optional on T3 and Sport grades.

Two enhancement packs have been developed to help create the ideal Aygo.

• Travel pack: includes a glovebox bag with CD pocket, trolley bag on wheels and a rucksack, all developed in partnership with the renowned Samsonite brand.
• Navigation pack: this features the Tom Tom Aygo, a clever and portable navigation system that’s easy to use with touch-screen operation. This option also provides a three-year package for warranty and map updates, body-coloured screen frames and integration of the dashboard and radio unit.

Aygo is offered at launch in July in three colours: Ice Blue, Carbon Quartz and Chilli Red.

SUPERIOR QUALITY IN SAFETY

Aygo is aiming to achieve the highest score in the A segment in official testing for impact protection. It features Toyota’s Minimal Intrusion Cabin System (MICS), a safety structure that reduces the risk of serious injury in an impact. This system also features in the Avensis and Corolla Verso models, both of which achieved the top five-star rating in Euro NCAP tests.

Aygo features comprehensive passive safety provisions with driver and front passenger airbags fitted as standard, with additional side airbags and ISOFIX child seat anchors standard on T3 and Sport models. Aygo is also equipped as standard with a seatbelt warning system with buzzer, a rare feature in A segment cars.

Aygo is also aiming for the best pedestrian impact protection in class, too. Design features to help achieve this include an energy absorbing structure in the front bumper, which deforms to channel impact forces and reduce leg injuries to a minimum.

Braking performance benefits from latest generation ABS and Electronic Brakeforce Distribution, fitted as standard to all Aygo models. The car’s headlights also provide one of the best illumination ranges in the segment.

SOLID AND CLEVER

Although Aygo is a compact city car, it rivals vehicles from higher segments in many areas. For example, its construction has a large high tensile steel content and most of the bodyshell is formed in galvanised steel. In addition, the rocker panel has a larger cross section that gives a more solid appearance and provides better anti-chip protection.

Aygo is powered by an all-new 1.0-litre VVT-i (Variable Valve Timing – intelligent) three-cylinder engine that delivers 67bhp (50kW) at 6,000rpm and 93Nm of torque at 3,600rpm. At 69kg, it is also the lightest engine available in a production car today.

The engine has class-leading power and torque for its size and in many cases outperforms engines with a larger displacement. It will also allow the Aygo to achieve record low fuel consumption and carbon dioxide emissions in the petrol A and sub-B segments: 61.4mpg and 109g/km are the combined cycle driving target figures

A revolutionary engine mount system drastically reduces the levels of noise and vibration. Instead of the conventional three-mount design, Aygo uses a mount on each side, positioned on a line that passes through the engine’s centre of gravity. The third engine mount at the bottom of the engine bay is replaced by a torque rod that efficiently suppresses the engine’s rotational movement during idling and acceleration.

From early 2006 Aygo will also be available with a 53bhp diesel engine, supplied by PSA Peugeot-Citroën. It is a development of a current PSA 69bhp 1.4-litre engine and the reduction in power improves reliability and brings emissions in line with Euro IV requirements.

Multi-mode Manual Transmission (MMT), Toyota’s manual transmission driven directly by electric motors, is available in Aygo. The system has automatic clutch operation and gives the driver the operation of fully automatic (E) mode and manual (M) mode. It is a less expensive alternative to conventional automatic transmissions and makes driving in busy city traffic much easier.

Electric Power Steering (EPS) is standard across the range. Along with a tight turning radius of 4.73m, it contributes to the car’s great manoeuvrability, ideal for town driving.

KEEPING COSTS DOWN

More than just creating a modern and dynamic urban car, Toyota has sought to achieve very low running costs and is targeting the segment’s lowest insurance groups for Aygo in the UK by securing the cheapest repair costs.

The Aygo 1.0 VVT-i will also require one the lowest cumulative maintenance times in its class at 4.2 hours up to 60,000 miles, ensuring low labour costs compared to rival models.

Aygo is also set to be the most fuel-efficient car in its segment, with a targeted combined cycle consumption figure of 61.4mpg, which means less time and money spent at the pumps.

For added peace of mind, every Aygo is protected by Toyota’s three-year/60,000-mile pan-European warranty, something which no other European competitor provides, plus a 12-year anti-corrosion warranty.

Toyota Financial Services is preparing several schemes that provide young, first-time buyers with more options to buy an Aygo. These include Trade Cycle Management, a special type of loan which allows the owner to change cars every two years, at no extra cost.

AYGO PRINCIPLE EQUIPMENT FEATURES

AYGO OPTION PACKS

AYGO TECHNICAL SPECIFICATIONS

THE NEW TOYOTA AVENSIS 2.2 D-4D AND 2.2 D-4D CLEAN POWER

Effortless performance with superior quality

KEY POINTS

• Two new 2.2-litre D-4D engines for Toyota Avensis presented at the Geneva Motor Show
• 2.2 D-4D
• Maximum power 148bhp and 310Nm from 2,000 to 3,200rpm
• Lightweight all-aluminium construction
• New, compact six-speed manual transmission
• Targeted top speed of 130mph and 0-62mph in 9.3 seconds
• Targeted combined fuel consumption of 47.1mpg and CO2 emissions of 157g/km
• Available in the UK from June 2005
• 2.2 D-4D Clean Power
• On sale in the UK in early 2006
• Class-leading performance: 175bhp and 400Nm from 2,000 to 2,600rpm
• Combined fuel consumption on average 20 per cent lower than rival engines with similar output (target figure)
• Lighter than most engines in segment, 11 per cent lighter than current 2.0-litre D-4D unit
• World’s lowest compression ratio for a production diesel engine, 15.8:1, aiding quieter operation and better performance from start-up
• Electrically-activated turbocharger with turbine wheel inertia reduced by 30 per cent for quicker engine response
• Toyota D-CAT system makes engine the cleanest on the market for combined nitrogen oxides (NOx) and particulate matter (PM) emissions
• Class-leading cost of ownership profile
• Both engines produced in Poland by Toyota Motor Industries Poland (TMIP)
• Complete Avensis engine range remains Euro IV compliant
• Avensis driving dynamics improved with new suspension settings and NVH package

INTRODUCTION

The Avensis has been a hugely successful car for Toyota in Europe. Now its driver appeal is to be increased with the introduction of two new 2.2-litre D-4D diesel engines. These will give the Avensis one of the most comprehensive product ranges in the D segment with three diesel (2.0, 2.2 148bhp and 2.2 175bhp) and four petrol (1.6, 1.8, 2.0 and 2.4) units. They also build on the Avensis’s achievement of offering an engine range fully compliant with Euro IV emissions standards, right from day one.

The first of the two new diesels to reach the UK market will be a 148bhp 2.2 D-4D unit. This uses a second generation common rail system to help achieve an excellent balance of performance and economy. The engine’s preliminary performance figures show 0-62mph acceleration in 9.3 seconds and combined cycle fuel consumption of 47.1mpg.

The second phase of the new diesel engine development will come in early 2006 with the introduction in the UK of a 175bhp version of the 2.2 D-4D that will launch Toyota’s revolutionary new concept for diesel engines, Clean Power. Clean Power features some of the world’s most innovative diesel technologies, some of them unique to Toyota.

Thanks to the incorporation of Toyota D-CAT (Diesel Clean Advanced Technology), the 2.2 D-4D Clean Power has the lowest combined NOx and PM emissions of any production diesel engine. At the same time, the engine also offers segment-leading levels of power and torque, 175bhp and 400Nm between 2,000 and 2,600rpm; the lowest levels of noise, vibration and harshness (NVH); and on average 20 per cent lower fuel consumption than engines of equivalent power output (target combined fuel consumption for the saloon model is 46.3mpg).

The two engines are being introduced together in other European markets, but in the UK their launch is to be staggered with the more powerful 2.2 D-4D Clean Power engine set to join the Avensis range at a later stage in the model’s life cycle. This decision takes into account the particular market conditions for D segment diesels in this country and the different specification structure for UK Avensis models.

Both engines are being built by Toyota Motor Industries Poland (TMIP) at Toyota’s newest factory in Europe. Toyota invested €200 million (approximately £140 million) to create the facility in Jelcz-Laskowice, which has an annual capacity of 150,000 engines and a work force of around 500 people.

TOYOTA 2.2-LITRE D-4D ENGINE

The first of Toyota’s new 2.2 D-4D engines to arrive in the UK market will be the standard 148bhp unit, joining the established 114bhp 2.0 D-4D in the Avensis range. In common with all other engines, petrol and diesel, powering the Avensis, the new unit complies with Euro IV emissions standards.

Owners will reap big benefits in terms of performance, refinement and running costs. Preliminary data for the new engine indicate a 130mph top speed and nought to 62mph acceleration in 9.3 seconds, while targeted figures for combined cycle fuel consumption and carbon dioxide emissions are 47.1mpg and 157g/km (hatchback and saloon versions).

Toyota is pushing forward diesel engineering by adopting an all-aluminium construction for the 2.2 D-4D. The subsequent weight saving over the more conventional iron build design helps contribute to the engine’s strong performance profile.

In common with the more powerful 2.2 D-4D Clean Power, the engine is matched to a new six-speed manual transmission that is compact and offers smoother and more precise gear changes. More details about the engine construction and transmission are given below.

TOYOTA 2.2 D-4D CLEAN POWER

The new 2.2 D-4D Clean Power is lighter than most engines in its class (1.9 to 2.2-litre), thanks to its all-aluminium construction, something that is still rare among diesel engines. Clever engineering measures include integration of the water and oil pump on the chain cover, reducing the oil pump’s weight by five per cent and its volume by 20 per cent. This contributes to making the engine 11 per cent lighter overall than the Avensis’s 2.0-litre D-4D engine.

Further reductions have been made in noise and vibration by adopting a balancer shaft. This substantially reduces booming – by up to 10dB at higher revs.

The Clean Power engine also has the lowest compression ratio of any production diesel engine: 15.8:1. This means the piston requires less effort to compress the air-fuel mixture, something that has been made possible by the use of an advanced common rail injection system and improved ceramic glow plugs that operate at much higher temperatures than previous D-4D engines (up 100° C to 1,175° C), enabling more efficient cold starting. Combustion is quieter and there is less build-up of heat in the piston bowl for a more efficient burn and, in turn better fuel economy and lower emissions.

The new engine uses the same cylinder liner material as Toyota’s current 1.4-litre D-4D engine, which has already shown superior wear resistance and good adhesion to aluminium.

NEW INJECTION AND INDUCTION TECHNOLOGIES

Most current common rail systems use solenoid injectors, actuated by a magnetic field generated by an electric current. By contrast, the new 2.2 D-4D Clean Power engine uses piezoelectric technology, a first in its displacement class.

The principle behind this technology is the capacity of certain materials to deform when an electrical charge is applied and return to their original state when the current is removed. This concept is applied to the new engine, with each injector composed of a stack of piezoelectric ceramic elements. When an electric current is applied to the stack, the elements instantly expand, allowing the fuel from the common rail to be injected into the cylinder. This means more fuel can be injected in a shorter time than is possible with conventional injectors. This in turn leads to greater fuel atomisation and more precise injection timing.

There are many advantages to this system. For instance, the new piezoelectric injectors operate 10 times quicker than solenoids when producing an injection and can perform up to five injections per cycle, with a single pilot injection at hot idle and multiple injection at partial load. With piezoelectric technology, pilot injection can be optimised, substantially reducing combustion noise.

Toyota’s piezoelectric common rail system produces the highest injection pressure (1800 bar) and the highest number if injections per cycle of any system of its type. Toyota is the first manufacturer to bring this diesel technology to the mainstream car market, first in the Avensis and with other models to follow.

The 2.2 D-4D Clean Power engine uses an electrically activated Variable Nozzle Turbocharger (VNT). The vanes of the VNT are installed in turbine housing and change position according to the speed of the gas flow. Rather than being activated by a step motor, they are triggered directly by a direct-current electric motor. This lets the engine ECU perform more precise and progressive activation of the vanes, helping increase turbocharger efficiency. Vane activation can also take place at lower engine speeds, if necessary. Compared with the 2.0 D-4D engine, the turbine wheel intertia has been lowered by 30 per cent, by reducing the number of blades and their thickness. This contributes to much quicker response at low speeds.

WORLD-BEATING EMISSIONS CONTROL SYSTEM

The new 2.2 D-4D Clean Power engine uses the revolutionary Toyota D-CAT system, which renders the high-performance engine the cleanest diesel power unit in the world in terms of combined nitrogen oxides (NOx) and particulate matter (PM) emissions.

D-CAT features a Diesel Particulate NOx Reduction (DPNR) four-way catalyst, the only system in the world which simultaneously reduces NOx and PM via the combination of a NOx-reduction catalyst and a particulate filter.

Effective operation of the DPNR is controlled by the engine management system varying the air-fuel ratio in the exhaust gases. To do this a fifth injector, the Exhaust Port Injector (EPI), injects fuel into the exhaust gas flow at a critical moment, creating the right stoichiometric conditions for the DPNR catalyst to reduce harmful emissions.

NEW SIX-SPEED MANUAL TRANSMISSION

The 2.2 D-4D and 2.2 D-4D Clean Power engines are matched to a new six-speed manual transmission designed for quick and precise gear changes. A multi-cone synchroniser is used from first to fourth gears, which requires less force in the gear shift action. It uses a slide ball bearing in the selector lever shaft and fork shaft for high shift efficiency, as well as a shift guide plate which reduces the amount of free play after a shift has been made. Shift smoothness is also improved by a re-shaped mass damper.

The new transmission is robust and exceptionally compact, measuring 384mm long. This is smaller than other six-speed units with identical or even inferior torque capacity. The unit has a three-axis construction which permits a 20 per cent reduction in length compared to a two-axis configuration.

The lowest viscosity oil available for manual transmissions is used, which contributes to a one per cent reduction in fuel consumption. Using an oil separator reduces losses, due to oil agitation. The transmission also offers a wider gear range, more than 7.0:1.

CLASS-LEADING COST OF OWNERSHIP

Toyota targets the cheapest running costs in segment for the Avensis, making the car an excellent proposition for fleet operators. Avensis currently has the best insurance rating in the UK (Groups 7 to 12 across the range), thanks to repair costs that are more than 20 per cent less than the segment average (9mph impact test with 40 per cent offset).

The Avensis’s strong cost of ownership credentials will be further strengthened with the introduction of the new 2.2-litre D-4D engine, thanks to its class-leading performance and low emissions.

The 2.2 D-4D engine matches the 2.0-litre unit in terms of cumulative maintenance time after 60,000 miles at 4.2 hours – the lowest figure in the diesel D segment. The new engine also accepts mineral oil, which is cheaper than the synthetic or semi-synthetic oil required for some other engines.

The engine features both an automatic belt adjuster and hydraulic valve compensators, which means there is no need for belt tension or valve clearance adjustments to be made during the engine’s lifetime.

IMPROVEMENTS IN DRIVING DYNAMICS

Along with the installation of the new 2.2 D-4D engine, the Avensis has been given an upgraded NVH package. This features an acoustic windshield, thicker bonnet insulator and extra sound insulation components in the engine compartment. The thickness of the floor and tunnel silencers has also been increased.

These measures make the Avensis 2.2 D-4D Clean Power the best in its class for booming noise and vibration.

The spring rate of the front anti-roll bar has been increased by 20 per cent, reducing body roll. The damping force of the front shock absorbers has also been increased, giving a flatter ride, and the capacity of the power steering pump has been intensified to allow for a quicker steering response.

TOYOTA 2.2 D-4D AND 2.2 D-4D CLEAN POWER PRELIMINARY TECHNICAL SPECIFICATIONS

* According to Directive 1999/100/EC

ENDS