Prototype of the pick-up with fuel cell drive in intensive testing phase

Production of the first ten units at Toyota Motor Manufacturing UK (TMUK)
Over 30 years of research and development work in the field of hydrogen
Project demonstrates importance of environmentally friendly drive technology

The Toyota Hilux with fuel cell drive has reached the testing and demonstration phase. Previously, the first ten units of the pick-up were manufactured at the British plant of Toyota Motor Manufacturing UK . The model was presented to the public for the first time in September 2023.

With the Hilux with fuel cell drive, Toyota is taking another step towards climate neutrality. With the project, the company is underlining its multi-path approach, which includes various drive concepts for different needs and markets - from hybrid and plug-in hybrid vehicles to pure electric cars, fuel cell models and combustion engines with e-fuels. The different mobility solutions are tailored to the respective regional requirements and lifestyles of the customers.

The first ten prototypes of the fuel cell Hilux have now been manufactured at Toyota Motor Manufacturing UK's Burnaston plant. Five vehicles are currently undergoing rigorous field testing to assess safety, performance, functionality and durability, collecting data from real-world test drives. Five more vehicles are being used for demonstration purposes for customers and the media, including at the upcoming Olympic and Paralympic Games in Paris. By familiarizing customers with hydrogen fuel cell technology, Toyota is laying the foundation for a successful future for the transport sector with this technology.

The knowledge gained from the Hilux project, together with Toyota's more than 30 years of research and development work in the field of hydrogen technology, will contribute to the next generation of fuel cell technology. These will be characterized by longer life cycles, greater range and significantly lower costs.

Toyota estimates that Europe will be one of the largest markets for fuel cells by 2030, with continued growth in mobility and energy generation. Therefore, Toyota Motor Europe (TME) announced the "Hydrogen Factory Europe" in December 2023 to promote the spread of hydrogen ecosystems and infrastructures here. The Hilux fuel cell project also plays an important role here.

Vehicle profile

The prototype of the Hilux with fuel cell drive is based on the legendary pick-up, whose name has stood for quality, durability and reliability for decades.

Since its launch in 1968, the Hilux has proven its invincibility time and again, conquering the North Pole, Icelandic volcanoes and the Antarctic continent, and winning three Dakar Rally races. The fuel cell Hilux maintains this uncompromising DNA while looking toward a carbon- neutral future.

From the outside, the prototype is indistinguishable from the standard Hilux; the dimensions remain unchanged at 5,325 x 1,855 x 1,810 millimeters (L x W x H). Under the hood is the fuel cell drive that has already been tested in the Toyota Mirai. This has proven itself in commercial use for almost a decade - since Toyota launched the first generation of the fuel cell sedan in 2015.

In the Hilux, the fuel cell drive has a range of up to 600 kilometers - more than could be achieved with a battery-electric drive. Thanks to the low weight of hydrogen, a higher payload and a higher towing capacity are achieved compared to other emission-free alternatives.

The hydrogen is stored in three high-pressure tanks, each with a capacity of 2.6 kilograms. These are installed in the ladder frame chassis of the pick-up. The polymer electrolyte fuel cell contains 330 cells and is arranged directly above the front axle. The Hilux with fuel cell drive is driven by an electric motor via the rear axle. The unit delivers an output of 134 kW (182 hp) and a maximum torque of 300 Nm. The only emissions produced during the journey are water vapor.

Part of the electricity generated by the fuel cell is temporarily stored in a lithium-ion battery that is housed under the loading area in the rear of the pick-up, directly above the hydrogen tanks, so that no space is lost in the driver's cab.

Project overview

The project began in early 2022 with a feasibility study conducted by TMUK and TME. The UK government then pledged funding through the Advanced Propulsion Centre, a non-profit organisation that supports the development of clean technologies and new mobility concepts. This enabled an intensive design and development programme to be launched from 1 July 2022 with consortium partners Ricardo, ETL, D2H Advanced Technologies, Thatcham Research and additional support from Toyota Motor Corporation (TMC).

The components were manufactured between February and May 2023 before the first prototype was built in a dedicated area at the TMUK factory according to Toyota's strict production principles. The design and development company Ricardo supported Toyota Manufacturing UK.

The actual prototype construction began in June 2023. The first vehicle was completed in just three weeks. A further nine prototypes were manufactured by the end of 2023 and underwent test bench and tests on special routes.

The ten prototypes will now undergo field and customer testing, marking the final phase of this research and demonstration project for the Hilux fuel cell vehicle.

Hydrogen solutions from Toyota

Toyota began developing hydrogen fuel cells in 1992. Since then, the company has continuously expanded its knowledge of this technology and promoted its use in a wide range of mobility applications; there are currently over 20 partners across Europe with whom Toyota is implementing hydrogen applications.

This includes a five-year trial of hydrogen-powered trucks to improve Toyota's carbon footprint in logistics and support the further development of sustainable hydrogen infrastructure across Europe.

Since July 2021, Toyota has also been building fuel cell buses together with its partner CaetanoBus. French company GCK, which is committed to clean mobility, is using Toyota's fuel cell modules to convert ten diesel buses into zero-emission vehicles and transport over 5,000 visitors during the Olympic and Paralympic Games in Paris.

Through its partnership with Norwegian company Corvus, Toyota has developed one of the safest and most advanced fuel cell systems for ships. Toyota also worked closely with Energy Observer to develop the first hydrogen-powered, zero-emission yacht that can be self-sufficient in energy.

Toyota fuel cells are also used for non-mobile applications. The modular fuel cells form the basis for the GEH2 generators from partner company EODev (Energy Observer Developments). In May 2021, these generators illuminated the Eiffel Tower in Paris with green, sustainable light - literally and figuratively.

Toyota’s development in the field of fuel cells

Based on its many years of experience, Toyota is developing the next generation of hydrogen fuel cells. This technology is expected to be characterized by longer life cycles and lower costs, thereby setting standards across the industry.

Toyota has been continuously developing the technology since 1992. In 2015, the Mirai was introduced, the world's first mass-produced hydrogen-powered sedan equipped with Toyota's first generation fuel cells. The second generation followed five years later with a range of around 650 kilometers, 30 percent more than its predecessor.

To exploit the technology's potential beyond the automotive industry, Toyota has repackaged its fuel cells in a compact modular form. The main components - the fuel cell stack, as well as the air supply, hydrogen supply, cooling and power control components - are integrated into a compact module that can be easily adapted to a wide range of products and applications. These modules are available in a box or in a flat, rectangular format to allow greater flexibility and easier adaptation to new applications.

The fuel cell modules are assembled in Europe at TME's R&D center in Belgium, which houses a line that combines advanced technologies with high-quality assembly. In the future, an increasing number of fuel cell systems will be manufactured here, at the Hydrogen Factory Europe, which will be closely linked to Toyota's other hydrogen activities, ensuring global reach and service.

A key element in Toyota's plan to increase the use of hydrogen is the new generation of fuel cells, which are currently under development and are scheduled to be launched on the market in 2026-2027. These systems will offer higher power density and an expected 20 percent longer range. Technical developments and higher production volumes will also reduce costs by more than a third.

Further research projects address the potential of scalable fuel cell stacks with different performance levels and the design of fuel tanks with complex shapes that are compatible with different vehicle sizes.

The partners of the consortium

Toyota Motor Manufacturing UK (TMUK)

In addition to its engine plant in Deeside, Wales, Toyota Motor Manufacturing UK (TMUK) manufactures the Toyota Corolla five-door hatchback and estate at its plant in Burnaston, England. The plant began operations in 1992 and later became the first site outside Japan to manufacture Toyota hybrid models. To date, Toyota has invested more than £2.75 billion in its UK manufacturing operations. Today, TMUK employs more than 3,000 people and supports many more jobs through its extensive supplier network.

Ricardo

The global engineering and environmental consulting company specializes in the areas of transport, energy and scarce resources. Ricardo supports the technical integration of the fuel cell components into the chassis of the Hilux.

ETL

European Thermodynamics delivers high integrity thermal solutions through outstanding design and innovation. The company is collaborating on the integration of advanced thermal management solutions in the fuel cell powered Hilux.

D2H

The D2H group of companies provides high-technology engineering services in simulation, modelling, aerodynamics, thermodynamics and design for motorsport and other industries and sectors. Their thermodynamic expertise is critical to the project.

Thatcham Research

Thatcham Research was founded in 1969 by the motor insurance industry to reduce the cost of insurance claims and maintain safety standards. Thatcham Research supports the project in relation to crashworthiness and insurance ratings.

Development of the Hydrogen-Powered Toyota Hilux Enters the Next Round