Over more than half a century, the Toyota Hilux has established a worldwide reputation for exceptional strength and durability, faithfully serving its owners and drivers in the world's most challenging environments. During that time, it has also constantly evolved to become a genuine dual-use vehicle: it has retained all the toughness and reliability required for serious work duties while offering the comfort, refinement, on-road poise and safety for day-to-day and leisure driving.
This evolution enters a new phase in 2025 with the introduction of the model's first electrified powertrain, the Toyota Hilux Hybrid 48V.
The 48V mild hybrid system strengthens the Hilux's proposition as an ideal partner for business and commercial users, delivering multiple benefits. Performance is smoother, quieter and more refined, whether driving on standard roads or tackling tougher terrain. Critically, this is achieved without compromising the pick-up's off-road prowess - notably there is no impact on its deep water (700 mm) wading or its load-carrying capabilities. This has been achieved by ensuring components such as the battery are positioned high up on the engine and using a fabric layer in the structure of the timing belt - a Toyota first.
The Toyota Hilux Hybrid 48V is launched in Double Cab format on all grades, including the flagship INVINCIBLE grade.
New Toyota 48V Hybrid system
The Hilux is the first model to use the new Toyota 48V Hybrid system. This mild hybrid powertrain retains the strengths of the pick-up's proven 2.8-litre turbodiesel engine and introduces a new electric motor-generator, a 48V lithium-ion hybrid battery and a DC-DC converter.
These new components have all been designed for simple integration, avoiding the need for complex adjustments to the powertrain layout.
Another key consideration was to ensure the system can withstand the kind of harsh operating conditions the Hilux is likely to encounter. For instance, new parts, including the motor-generator, are located high enough on the engine to maintain the vehicle's 700 mm wading capability.
Electric motor-generator
The electric motor-generator - a permanent magnet synchronous unit - is driven by the engine and in turn charges the lithium-ion hybrid battery. It provides multiple benefits that make driving easier, smoother and quieter in all conditions - both on-road and off.
Its compact dimensions helped make the hybrid system easy to integrate with Hilux's existing powertrain.
Its benefits include a regenerative braking function, recovering energy produced every time the driver comes off the throttle. Combined with engine braking, this saves fuel, makes driving easier and gives natural-feeling deceleration.
In on-road driving, acceleration when starting off and deceleration are smoother, more linear and more natural-feeling, contributing to a more composed and comfortable ride.
When covering rougher, off-road surfaces, the motor generator enhances the Hilux's ability to overcome obstacles. Controllability at low speeds is further helped by a 20% reduction in the engine's idling speed, from 720 rpm to 600 rpm.
The power assistance provided by the electric motor-generator also reduces the engine load in low-efficiency running, contributing to up to a 5% improvement in fuel consumption and CO2 emissions, compared to the 2.8-litre diesel Hilux without the Hybrid 48V system.
The motor-generator's operating status is indicated in the driver's multi-information display with a read-out showing CHG (energy regeneration), ECO and PWR (providing assist in both cases).
Smoother, quicker, quieter stop-start performance
The stop-start system delivers a more comfortable drive in traffic, with the 48V Hybrid system enabling quicker and quieter restart response.
The electric motor-generator operates in place of a conventional starter motor and is always connected which means restart is enabled even at high engine speeds and there is less delay in immediate restarts after stopping.
Auto-stopping is provided in heavy traffic, or at times when the driver accidentally restarts the engine by reducing their pressure on the brake pedal.
The driver can set their preference for stop and start performance, selecting NORMAL or LONG in the vehicle's multi-information display. When choosing LONG, the engine's idling stop time when the air conditioning is operating is increased.
When the Hilux is on an uphill gradient, a slight delay might occur between engine restart and the generation of drive torque. As an auxiliary function, the stop and start system will maintain brake pressure until the necessary drive torque is generated, to support smooth start-off performance. Also, on level surfaces, any excess drive torque from the engine speed racing on restart is offset.
Injection volume control has been optimised to support the system's responsiveness, balanced against the level of shock experienced during acceleration.
Lithium-ion hybrid battery
The 48V lithium-ion hybrid battery has 13 cells and a 4.3 Ah capacity. It weighs just 7.6 kg and, thanks to the use of small internal components, is sufficiently compact to be housed below the Hilux's rear seats, with minimal impact on cabin space.
When fully charged, the battery can supply up to an additional 12 kW of power and 65 Nm of torque to the powertrain at start-off.
Both the hybrid battery and the low-profile DC-DC converter are protected against water ingress, cooling air is drawn into the battery from the front of the vehicle, with a lower temperature than the cabin air. A filter helps prevent the build-up of dust in the battery's cooling paths and fan, which helps prevent deterioration of battery performance from high temperatures.
Two-arm belt-tensioner
A two-arm tensioner provides the belt tension required by the electric motor-generator. The first of its kind to be used in a Toyota, it has been designed specifically for use in diesel engine vehicles and to meet the demands of rough-road driving. It provides the level of belt tension the motor-generator requires, plus a restart assist function.
It also helps secure improved acceleration response and its noise and vibration performance is on par with gasoline engine passenger vehicles.
The belt's material composition is key to its performance. A high-strength cotton fabric layer on the ribbed side of the belt reduces noise, absorbs water and maintains its friction coefficient when wet. This helps achieve consistent performance in challenging conditions, for example when driving through water. Not only can the Hilux 48V wade through water 700 mm deep, it can be stopped at this depth for up to 10 minutes.
A high-strength aramid cord is used at the core of the belt, enhancing reliability when tension increases are experienced when the motor-generator starts the engine or the increases the level of power generation.
Stoppers in the tensioner arms reduce abnormal noise and vibration caused by the arms striking the housing when switching to motor-generator mode. Bushes in the damping mechanism are designed to help prevent foreign bodies entering the sliding parts, such as dust and grit in rough road driving.
2.8-litre turbodiesel engine
The Hilux's engine, a DOHC 16-valve unit, generates a maximum 204 DIN hp (150 kW) at 3,400 rpm and a muscular 500 Nm of torque between 1,600 and 2,800 rpm. It features common rail fuel injection, a variable nozzle turbocharger and a water-cooled intercooler. Exhaust emission control features include a particulate filter, Selective Catalytic Reduction and additional urea injection. In common with other Hilux models, the Hybrid 48V is compatible with HVO100 diesel, a non-fossil fuel made from 100% renewable sources.
New Multi-Terrain Select (MTS)
The Toyota Hilux Hybrid 48V is the first Hilux to feature the Multi-Terrain Select system, operated using the MTS switch and mode selector on the centre console. This adjusts the vehicle's drive control systems - drive force, suspension and hydraulic brake pressure - to enhance traction, manoeuvrability and stability in different driving conditions.
There are six settings: Sand, Mud, Rock, Dirt, Deep Snow and Auto. In Auto mode, sensors around the vehicle continuously assess the road conditions and automatically apply the appropriate control settings. Sand, Mud, Rock and Auto can be engaged when the Hilux is in (low) L4 running; Dirt, Sand, Mud, Deep Snow and Auto can be used in the H4 transmission range.
The Hilux's digital multi-information display features a different background for each mode. In Sand, Mud and Deep Snow modes in H4 and in all L4 modes, the VSC OFF indicator is illuminated; in all modes, the slip indicator light will flash on and off when brake control is being applied.
A strong, stable ride
The new Toyota Hilux Hybrid 48V has plenty of street presence, measuring 5,325 mm long, up to 1,900 mm wide and 1,865 mm high. It's a practical pick-up, the double cab format matched to a 1,555 mm long bed. The mild hybrid system in no way diminishes the load-carrying capability: payload is up to 1,000 kg and towing capacity is 3,500 kg.
Toyota Hilux Hybrid 48V has a body-on-frame architecture and ladder frame chassis which are key to its strength, durability and torsional rigidity. The rear suspension's hard-wearing leaf springs and twin shock absorbers provide sure-footed off-road performance and SUV-like on-road comfort and handling. It's "go-anywhere" credentials are support by a running ground clearance of 310 mm and approach and departure angles at 29 and 26 degrees respectively.
Advanced safety provisions
The Hilux Hybrid 48V is equipped with Toyota Safety Sense technology to provide occupants and other road users with world-class protection from many common accident risks.
An enhanced Pre-Collision System (PCS) can better detect pedestrians at night, bicyclists during daytime, and oncoming vehicles or pedestrians at intersections when making turns. When such hazards are detected, the system issues audible and visual alerts before applying braking force if required.
Adaptive Cruise Control (ACC) with Road Sign Assist (RSA) allows the driver to quickly adjust the speed in line with changes in the limit. The ACC can also automatically slow the vehicle to ensure an appropriate speed through highway bends.
When driving at night, the Automatic High Beam (AHB) function eliminates the need to switch headlight levels to avoid dazzling other drivers. It detects approaching vehicles and instantly and precisely adjusts the lights, so high beam use is maximised.
Multimedia and connectivity
The high equipment specification includes the eight-inch Toyota Smart Connect multimedia system and a nine-speaker JBL premium audio package.
Toyota Smart Connect gives the driver access to cloud-based navigation with efficient journey planning helped by up-to-the-minute traffic intelligence. The system also includes a voice agent for hands-free operation of mobile phone calls and audio functions. Smartphone integration is provided wirelessly via both Apple CarPlay® and Android Auto®.
Further convenience is provided by the MyToyota smartphone app. This can be used to operate certain vehicle functions remotely - door locking/unlocking and use of the air conditioning system to warm or cool the cabin ahead of a journey. The app also provides vehicle data and can be used for servicing scheduling and reminders.
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