Toyota Auris HSD (2011)

Hybrid Synergy Drive® A Unique Eco Driving Experience

The Toyota Auris HSD drives like no other car in its class. It is equipped with the first and only full hybrid powertrain in the C-segment. Its introduction will create an important shift in customer perceptions of full hybrid technology.

The advantages of exceptional fuel efficiency and low CO2 emissions are obvious. However, the Auris HSD customer will also experience a smooth and sophisticated, relaxed and stress-free driving experience thanks to the everyday usability, driving comfort and remarkable quietness of Toyota's multiple award-winning powertrain.

Named International Engine of the Year in 2004, Green Engine of the Year and Best Fuel Economy Engine of the Year for the fifth consecutive year in 2008, Toyota's Hybrid Synergy Drive® represents the ultimate synergy of high technology and environmentally-conscientious forward thinking in powertrain design.

The Unrivalled Efficiency Of Toyota's Full Hybrid Technology

Unlike rival, mild hybrid vehicles, the Toyota Auris HSD is a full hybrid capable of operating in petrol and electric modes alone, as well as a combination of both. Its advanced Hybrid Synergy Drive® system delivers the energy-saving benefits of a series hybrid combined with the performance benefits of a parallel hybrid.

Full hybrid technology equips the new Toyota hatchback with instant power, impressive, seamless acceleration and remarkably quiet operation, yet returns class-leading fuel efficiency and the lowest possible emissions.

In combination, the Hybrid Synergy Drive® system's 1.8 litre VVT-i petrol engine and electric motor generate a maximum power output of 136 DIN hp, equipping the Auris HSD with a 0-100 km/h acceleration time of 11.4 seconds and a maximum speed of 180 km/h - performance to match any conventional 2.0 litre diesel or petrol hatchback.

Conversely, the Auris full hybrid returns fuel consumption figures of only 3.8 l/100 km in the European homologation combined cycle and targets remarkably low, highly tax-efficient CO2 emissions of just 89 g/km. In addition, the Toyota Auris HSD generates significantly lower NOX and PM emissions than diesel engined cars of comparable performance.

Moreover, when operating in a unique, switchable EV mode, the Auris HSD offers zero CO2, NOX and PM emissions, driving for up to about two kilometres at speeds of up to about 50 km/h, dependant on battery charge and driving conditions.

Hybrid Synergy Drive® system architecture

The Toyota Auris HSD's latest generation series/parallel full hybrid system features a 1.8 litre VVT-i petrol engine, a powerful electric motor, a generator, a high performance battery, a power control unit and a power split device which employs a planetary gear set to combine and re-allocate power from the engine, electric motor and generator according to operational requirements.

Key to the successful installation of Hybrid Synergy Drive® within the Auris HSD's front-engined hatchback platform, the electric motor, generator and power split device are all housed in one lightweight, highly compact transmission casing directly comparable in size to that of a conventional gearbox.

The full hybrid drive system's seamless, E-CVT electric continuously variable transmission is controlled by Shift-by-Wire technology, using an electric shift lever system.

Powered by the hybrid battery, the electric motor works in tandem with the petrol engine to boost acceleration during normal driving. Unique to Toyota's full hybrid drive technology, the electric motor alone powers the driven wheels when the Toyota Auris HSD is operating in EV mode.

During deceleration and under braking, the electric motor acts as a high-output generator to effect regenerative braking. Normally wasted as heat, kinetic energy is recovered as electrical energy for storage in the high performance battery.

1.8 Litre Atkinson Cycle Engine

The lightweight, highly compact, 4-cylinder 1798 cc Atkinson cycle petrol engine develops max output of 73 kw/99 DIN hp at 5200 rpm and max torque of 142 Nm at 4000 rpm.

Combined with a cooling Exhaust Gas Recirculation system, the adoption of the Atkinson cycle offers significant gains in fuel efficiency and the reduction of emissions.

Because the intake valves close late in an Atkinson Cycle engine, compression is delayed. This creates a high expansion ratio for less compression, reducing intake and exhaust energy losses and converting combustion energy to engine power more effectively. As a result, the exhaust temperature is lower than that of conventional engines. The cooling Exhaust Gas Recirculation system reduces cooling loss and pumping loss and consequently fuel efficiency is enhanced. Heat tolerant catalyst adoption is mostly contributing to reduction of enrichment.

The 1.8 litre engine features numerous further enhancements to both improve performance and help minimise fuel consumption and emissions. VVT-i (Variable Valve Timing-intelligent) helps boost response levels across the entire rev range by varying the air-fuel intake and exhaust valve timing to suit the conditions at any given time. As well as improving torque at low and medium engine speeds, the system also reduces emissions and enhances fuel efficiency.

In addition, the engine features roller rocker arm valve-train control, a resin intake manifold with an optimised port configuration and 12-hole, atomising, long nozzle injectors. Thin, long reach spark plugs contribute to enhanced anti-knocking performance, and low tension piston rings, reduced piston friction, a standing oil jet for piston cooling and a stainless steel pipe exhaust manifold further enhance engine efficiency. In combination, these advanced technologies contribute to improved power output with reductions in both fuel consumption and emissions.

Ultra-low Noise, Vibration and Harshness (NVH) characteristics are one of the key attributes of Hybrid Synergy Drive® and particular attention has been paid to minimising engine noise and vibration. The rigidity of engine parts including the cylinder block and crank case has been optimised through in-depth Computer Aided Engineering (CAE) analysis. A highly rigid, ribbed aluminium cylinder head cover combines light weight with reduced noise and vibration.

The engine itself is mounted on a 4-point mounting system with mounting rubber characteristics optimised for the suppression of noise and vibration. And dynamic damper is integrated within the engine mount to further minimise noise and vibration, as well as reducing engine start/stop shock.

Hybrid Transaxle with Electric Continuously Variable Transmission (E-CVT)

Housing the electric motor, generator, power split device and a reduction gear in one lightweight, highly compact transmission casing directly comparable in size to that of a conventional gearbox, the transaxle lies at the heart of the Hybrid Synergy Drive® system.

The full hybrid drive system's seamless, E-CVT electric continuously variable transmission is controlled by Shift-by-Wire technology, using an electric shift lever system. The shift lever itself is designed to always return to its 'home' position when released and the shift position can be checked on the shift position indicator integrated within the driver's instrument cluster.

Adjacent to the shift lever, a parking switch with integral indicator light is used to engage or release a parking lock mechanism within the transmission gearing. The parking lock is automatically deactivated when driving off and automatically re-engages when the car is switched off.

The transaxle features a multi-function gear train making it lightweight and highly compact. Numerous measures have been adopted to reduce component noise and drive shaft energy losses, lowering hybrid system fuel consumption. The world's first internal tooth shaving process offers enhanced planetary ring gear precision, minimising transmission noise. The lubrication system has been designed to reduce stirring and the use of ball bearings minimises transaxle component friction.

Electric Motor/Generator

The high performance, permanent magnet, synchronous electric motor/generator has a maximum power output of 60 kW. It works in tandem with the petrol engine to boost acceleration and power the driven wheels alone when the Auris HSD is operating in EV mode.

Generating instant power and a maximum 207 Nm of torque the motor is six times more powerful than that of rival, mild hybrid systems. It is air cooled and maximum drive voltage amplification is 650 Vdc. However, under ordinary driving conditions, unless maximum output is required, the motor is driven at an unamplified voltage whenever possible to enhance fuel efficiency.

High Output Battery

The battery pack uses proven and reliable nickel-metal hydride technology. It is located beneath the rear loadspace floor, minimising impact on cabin accommodation and giving the Auris HSD a luggage capacity of 279 litres.

Power Control Unit

Similar in size to a 12 volt battery, the Hybrid Synergy Drive® power control unit (PCU) consists of a voltage boost converter, an inverter and a DC/DC converter, controlled by a motor control ECU which receives commands from the hybrid vehicle control ECU.

The inverter converts the battery's direct current into a 650 volt alternating current to drive the electric motor and occasionally, the generator, offering significantly improved PCU performance.

A conventional, non-hybrid vehicle is equipped with an alternator to charge the auxiliary battery. However, because an alternator cannot operate during engine cut-off driving mode, a full hybrid vehicle requires an alternative system. Hybrid Synergy Drive® incorporates a DC/DC converter to reduce the high voltage of the 202 V system battery pack to 14 V, supplying power to the accessory systems and charging the auxiliary battery.

Hybrid Synergy Drive® In Operation

Over the course of any journey, Toyota's Hybrid Synergy Drive® system operates in several different modes to maximise the Toyota Auris HSD's overall efficiency.

At rest, the engine stops automatically to conserve fuel. Under operating conditions of low engine efficiency such as start up and low to mid-range speeds, the vehicle automatically runs in EV mode, on the electric motor alone, thus eliminating CO2, NOX and PM emissions.

Under normal driving conditions, power allocation is constantly adjusted between engine and electric motor to combine optimum performance with maximum fuel efficiency.

Via an Electronically Controlled Braking System, the electric motor acts as high-output generator during deceleration and under braking to effect regenerative braking, optimising energy management in the Hybrid Synergy Drive® system by recovering kinetic energy (normally wasted as heat under braking and deceleration) as electrical energy for storage in the high performance battery.

Battery power level is constantly managed via an engine driven generator to obviate any requirement to recharge the system from an external source.

Three on-demand Driving Modes - A Unique Eco Driving Experience

Supplementing the NORMAL drive mode, three alternative, 'on-demand' drive modes - EV, ECO and POWER - may be selected to further increase driving efficiency, performance and fuel economy.

From start up and at speeds of less than 50 km/h with the NORMAL drive mode selected, the Toyota Auris HSD automatically operates in EV mode depending on driving conditions and battery charge, driving under electric motor power alone to give instant power and an extraordinarily smooth, quiet ride with minimal NVH. This unique driving mode is not available to drivers of mild hybrid vehicles, requiring the full hybrid technology of Hybrid Synergy Drive®.

Though the petrol engine will still start if the system judges that its output is necessary, the switchable EV mode allows for significantly greater throttle inputs without engine start up. Hence, with vehicle range dictated by battery charge, the EV drive mode allows for urban driving with minimal noise and zero CO2, NOX and PM emissions for up to two kilometres. Because the use of only light to medium throttle inputs keeps the petrol engine switched off throughout its operation, the EV drive mode contributes to a significant reduction in the Toyota Auris HSD's overall fuel consumption.

In ECO mode, throttle response to aggressive accelerator pedal inputs is reduced and air-conditioning control optimized for improved fuel economy.

A POWER mode also modifies the response of the Toyota Auris HSD to throttle inputs, here boosting power to improve acceleration and enhance driving pleasure. The POWER mode provides a 25% higher throttle response to accelerator pedal input.

Complimenting these three on-demand drive modes, an Eco Drive Monitor helps drivers maximise the fuel efficiency of Toyota's full hybrid powertrain. Via the multi-information indicator in the instrument cluster, drivers may monitor the flow of energy within the Hybrid Synergy Drive® system for each driving mode. This helps them develop relaxed, fuel efficient driving techniques and maximise system efficiency.

In addition, a simple yet clear power consumption gauge in the combination meter shows how much power is being used or generated at any given time.

Comfortable, Ultra-Quiet Driving with low NVH level

The Auris HSD brings the extraordinarily refined, smooth and silent Hybrid Synergy Drive® experience to European C-segment customers for the first time.

In order to maximise the unique benefits of Toyota's full hybrid drive system, the Auris HSD features numerous body, chassis, suspension and steering modifications to the recently launched Auris 2010 model range.

HSD Adapted Bodyshell

The centre floor body of the Toyota Auris HSD has been redesigned to accommodate the Hybrid Synergy Drive® battery pack, which is located beneath the rear loadspace floor. Minimising impact on cabin accommodation, this gives the new Toyota full hybrid a luggage capacity of 279 litres.

Tuned Suspension

Through collaboration between the Japanese R & D suspension design team and Toyota's European R & D conformity testing team, the Auris HSD's ride and handling has been fine-tuned specifically for the customers and roads of the European market. It combines stable high speed driving performance with secure handling and superior ride comfort.

The front suspension features a variation of the highly effective MacPherson strut, known as an L-arm MacPherson strut. This compact and highly rigid design brings the strut in-board from the wheel hub, which allows for a wider track with superior stability and excellent noise and vibration suppression.

The rear suspension benefits from a highly efficient torsion beam system featuring a separate spring and damper layout, creating a super-compact design which does not intrude into the vehicle's loadspace.

Compensating for a change in weight distribution effected by the installation of the hybrid battery pack to the rear, both the Toyota Auris HSD's front and rear dampers have been tuned for optimum ride quality.

Lowered Chassis with Bespoke Wheels and Tyres

In conjunction with numerous aerodynamic bodywork details designed to maximise the fuel efficiency of the full hybrid drive system and minimise wind noise during high speed cruising, the Auris HSD's ride height has been lowered by 5 mm to further enhance aerodynamic efficiency and high speed stability.

In addition, it has been equipped with unique, 15" or 17" Prius-style aero wheels with enlarged air gaps for improved cooling air flow to the Electronically Controlled Braking System and 195/65R 15 or 215/45R 17 low rolling resistance tyres (latest generation).

Electronically Controlled Braking System

The Auris HSD's full hybrid drive system incorporates an Electronically Controlled Braking System which coordinates the control of both hydraulic and regenerative braking and is 18% lighter and 31% smaller than conventional systems.

The system is equipped with ventilated disc brakes to the front -273 mm for 15" wheels and 296 mm for 17" wheels- and 259 mm solid discs to the rear for optimum braking efficiency. Coordinated control of the hydraulic and regenerative braking systems maximises the regeneration of energy by the electric motor during deceleration and under braking.

Revised Electric Power Steering (EPS)

With a quick ratio of 14.44:1 and just 2.9 turns lock-to-lock, the Toyota Auris HSD's speed-sensitive Electric Power Steering (EPS) reduces hybrid system energy consumption for improved fuel economy.

The EPS' compact, high output motor and torque sensor are built into the steering column, optimising steering assistance for more precise control of the vehicle. EPS improves fuel economy by consuming power only when steering force assistance is needed. It is highly durable and requires no hydraulic fluid.

Compensating for the change in weight distribution effected by the installation of the hybrid battery pack to the rear, as well as the re-tuned suspension, the Auris HSD's EPS has also been revised to maintain optimum feedback and vehicle agility.

Low Noise, Vibration and Harshness (NVH)

Reinforcing the extensive Noise, Vibration and Harshness (NVH) suppression measures inherent in the Auris HSD's aerodynamic styling and ultra-quiet Hybrid Synergy Drive® system, particular attention has been paid to noise and vibration reduction within its highly rigid, impact absorbing body structure.

The engine is mounted on a 4-point system incorporating dynamic damper for maximum suppression of noise and vibration as well as reduced engine start/stop shock.

Road and engine noise have been rigorously suppressed through the comprehensive use of high-performance sound proofing materials throughout the engine and passenger compartments. An acoustic windscreen design further reduces wind noise for improved quietness at cruising speeds.

As a result, the new Toyota full hybrid sets the highest standards in Noise, Vibration and Harshness (NVH) reduction, sound absorption and vibration damping. This ensures customers enjoy a cabin environment of unequalled calm and quietness at all vehicle speeds.

Low Cost Of Ownership

Its segment-first, full hybrid drive technology offering customers with an unparalleled combination of low maintenance, insurance and running costs with high reliability and residual values, the Toyota Auris HSD represents outstanding value for money.

Best-in-class CO2 emissions of just 89 g/km and combined cycle fuel economy of only 3.8 l/100 km offer customers significant, pan-European tax incentives, inner city congestion charge exemption and exceptionally low running costs.

The Toyota Auris HSD's full hybrid drive system has been specifically designed for low maintenance and exceptional durability. Combining low parts pricing with short service times and hence, reduced labour costs, Auris HSD maintenance costs over 100,000 km are remarkably reasonable.

The outstanding reliability of Hybrid Synergy Drive® has already been proven through its installation in the Prius, which shows the lowest warranty cost per unit amongst all Toyota models. The Toyota Auris HSD benefits from a three year/100,000 km warranty, extended to five years/100,000 km on hybrid system components.

The Auris HSD is expected to achieve highly competitive insurance ratings, while residual values are expected to be in line with vehicles at the top of the C-segment. In the case of the UK market, a residual value target of 38-39% (depending on model grade) after 36 months/60,000 miles is anticipated.

Low CO2 taxation and fuel costs

The Toyota Auris HSD fulfils Euro 5 emissions standards and is expected to meet those of Euro VI. Producing best-in-class CO2 emissions of just 89 g/km - a figure unmatched by any other C-segment car - the Toyota full hybrid offers customers significant tax incentives in several European countries; for instance, 2,000 Euros in France and 6,400 Euros in The Netherlands.

Toyota Auris HSD customers also benefit from class-leading fuel efficiency. Whilst operating in NORMAL driving mode, the new Toyota full hybrid returns only 3.8 l/100 km in the European homologation combined cycle. With the fuel consumption levels of a small city car, the Auris HSD has a driving range of about 1,180 km on a single tank of fuel.

This remarkable fuel efficiency is further enhanced by the Toyota Auris HSD's ability to operate in a unique, switchable, EV mode. Unavailable to rival, mild hybrid vehicles, EV mode allows the Toyota full hybrid to run on electric motor power alone for about 2 kilometres at speeds of up to about 50 km/h, depending on battery charge and driving conditions, whilst generating zero CO2, NOX and PM emissions.

Auris HSD running costs are likely to be subject to further reductions with the implementation of future congestion charging plans in major European cities. In London, for instance, the Auris HSD's hybrid vehicle status grants it exemption from the statutory charge when entering the Congestion Zone, representing a considerable annual cost saving for the urban dweller and customers who regularly travel into the city centre.

Lower servicing costs with outstanding component longevity

The Toyota Auris HSD's 15,000 km service interval maximises component lifetime efficiency, while the latest generation Hybrid Synergy Drive® system has been specifically designed for low maintenance and outstanding durability.

The full hybrid powertrain has no need of a conventional starter motor or alternator. The engine is equipped with a maintenance-free timing chain - a serving cost saving of some 300 Euros, an element oil filter and miniaturised spark plugs - realising savings of 45% and 23% respectively. It also has no drive belts whatsoever, combining excellent reliability with a further saving of some 80 Euros.

Due to the efficiency of the Auris HSD's Electronically Controlled Braking System, the brake pads have a life expectancy of over 100,000 km and may never need to be replaced during the vehicle's lifespan. Standard sized 15" and 17" tyres not only cost less than purpose-made alternatives, but also their high, 2.4 and 2.3 bar pressure significantly reduces wear, with typical durability exceeding 50,000 km.

With a proven reliability record garnered over some 60 billion kilometres of driving worldwide, the high quality Hybrid Synergy Drive® battery is designed to last the entire life of the car. Rigorously assessed for performance and durability, it is covered by a five year, 100,000 km warranty. Exhaust system life expectancy is over five years due to a high stainless steel content, and 'lifetime' LED headlamp bulbs have a 20 year lifespan.

Combining exceptional component longevity with low parts pricing and the reduced labour costs resultant from short service times, Toyota Auris HSD maintenance costs over 100,000 km are highly competitive.

The Toyota Auris HSD benefits from a three year/100,000 km warranty, extended to five years/100,000 km on hybrid system components. Prius warranty history has already confirmed the outstanding reliability of Hybrid Synergy Drive®, showing the lowest warranty cost per unit amongst all Toyota models. Over three years, Prius warranty cost per unit is only 18% of that of the Corolla/Avensis, of which just 1.8% relates to hybrid componentry - figures the Auris HSD is fully expected to equal.

Proven Toyota quality with competitive insurance costs and high residual values

With proven Toyota quality and Hybrid Synergy Drive® reliability already exemplified through the Prius' top 'Lowest Problems' ranking in JD Power's 2007 and 2008 German, French and UK surveys, the Auris HSD will bring an unprecedented level of customer satisfaction to the C-segment.

The Toyota Auris HSD bodyshell has been designed to resist corrosion throughout the life of the vehicle. The use of galvanized steel sheets on most of the body components enhances anti-corrosion characteristics. And an underbody undercoating further prevents corrosion damage as a result of paint chipping.

The Auris HSD also benefits from Toyota's already excellent record of low repair costs. Many components have been developed specifically to reduce impact repair costs and the body structure itself has also been designed to reduce repair costs when a minor collision occurs.

The crash box integral to the bumper reinforcement absorbs collision energy, helping to reduce body structure damage. The bumper reinforcement, front side member, radiator support, rear bumper crash box and rear side member all adopt bolt-fastening structures for reduced repair costs. And the radiator support features a retracting mechanism to minimise damage to the cooling unit in the event of a minor collision.

The Auris HSD is expected to achieve highly competitive C-segment insurance ratings, and residual values are expected to be in line with vehicles at the top of the C-segment. In the case of the UK market, a residual value target of 38-39% (depending on model grade) after 36 months/60,000 miles is anticipated.

Design

The Toyota Auris HSD builds on the dynamic exterior design changes and extensive interior improvements in quality, materials, ergonomics, driving comfort and visual appeal introduced with the recent launch of the Auris 2010 model range.

Externally, the new Toyota full hybrid incorporates several unique styling details to improve the car's aerodynamic performance and the fuel efficiency of its Hybrid Synergy Drive® powertrain. The interior incorporates hybrid-specific instruments, switchgear and upholstery.

Exterior Design: Improved Aerodynamic Efficiency

Toyota's new, full hybrid hatchback shares the long, 2,600 mm wheelbase and 4,245 mm overall length of the Auris 2010 model range, while a 5 mm lowering of vehicle ride height further improves its aerodynamic efficiency.

The Auris HSD features the new, horizontal bar-type grille and more aggressive headlamp clusters of the 2010 model range. However, the full hybrid's upper grille opening has been optimised to help the air flow smoothly over the upper half of the body and incorporates a hybrid blue Toyota symbol.

The front bumper and front spoiler design have also been revised and the size of the lower grille has been enlarged to reduce airflow resistance as well as improving engine cooling efficiency.

Redesigned bumper corners house a revised foglamp configuration incorporating HSD-unique LED daytime running lights. The flat, vertical surface of the bumper corner not only reinforces the Auris HSD's broad stance and driving stability, but also corrects airflow as it passes over the front wheels to minimise wheel arch turbulence.

In profile, the Toyota Auris HSD may be identified by front wing hybrid badging and a choice of purpose-made, 15" or 17" alloy wheels with integrated, aerodynamic caps and low rolling resistance tyres. These Prius-style aero wheels feature enlarged air gaps for improved cooling air flow to the Electronically Controlled Braking System. In addition, a large, roof mounted rear spoiler further improves the Auris HSD's aerodynamic efficiency.

To the rear, the Auris HSD shares the stronger, more confident design of the 2010 model range. This features a 'catamaran' bumper profile which accentuates the fill hybrid's muscular proportions and wide track. The presence of Hybrid Synergy Drive® is indicated by hybrid-specific badging and a hybrid blue Toyota symbol.

Acting in combination to smooth and control the flow of air over the car, these HSD-specific design modifications have reduced the Toyota hybrid's coefficient of drag from Cd 0.293 to 0.283, effecting reductions in both fuel consumption and CO2 emissions.

The Toyota Auris HSD is available in a choice of six exterior colours, including a new, hybrid-specific, pearl white finish.

Interior Design: Hybrid-Specific Instruments, Switchgear and Upholstery

The Auris HSD's interior benefits from all the improvements in quality, ergonomics and visual appeal of the 2010 model range. Soft touch materials cover the top of the driver's instrument cluster and the upper glove box and the centre console storage box functions as an armrest. A comfortable steering wheel incorporates audio and Bluetooth phone control switches.

The unique, bridged centre console which brings the gear lever, handbrake and instrumentation within the closest possible reach of the driver has a bright metallic finish matched by the door handles. Control panel colour and finish changes have enhanced switch layout visibility. Revised throughout the Auris 2010 model range, the handbrake design features a new lever release button, a tactile, ergonomic grip and lower seating in the release position.

In addition, in conjunction with the presence of Hybrid Synergy Drive®, the Auris HSD interior also features several significant modifications. The driver's instrument binnacle has been revised, with the tachometer replaced by an Eco Drive Assist Monitor. The centre-dial information panel includes additional, Hybrid Synergy Drive® - specific information such as Energy Flow and Eco Drive Result monitors.

A hybrid blue Smart Start switch has been added to the side of the instrument cluster. The centre console incorporates a Parking Control switch, EV, Eco and Power drive mode switches and a hybrid blue Shift-by-Wire transmission lever with a high-quality silver paint finish.

Toyota Auris HSD instrument and switchgear illumination has been amended to white numbers on a hybrid blue background for the Optitron meter panel, greenish white colour - night illumination - is used on Smart start switch, Audio unit, P control switch, drive mode switch and heater control panel.

The Toyota Auris HSD interior is finished in Dark Grey. A choice of hybrid-specific upholstery features a standard specification, blue-flecked seat panel fabric, while high grade models are trimmed in Alcantara panels with leather surrounds.

Manufacturing

The Auris HSD will be assembled at Toyota Manufacturing UK's Burnaston plant, in Derbyshire, while the Hybrid Synergy Drive® system's petrol engine will be built in Deeside. Opened in 1992, Burnaston was Toyota's first European plant and vehicle production passed the three million mark in June 2010.

After almost 20 years of manufacturing experience, the Auris HSD represents a major milestone for TMUK, with Burnaston now becoming the first Toyota plant in Europe to produce a hybrid vehicle.

An Auris HSD is built from 1,753 separate components, of which 395 - some 25% - are unique to the hybrid model derivative. This adds significant production complexity, with 149 build processes - 69% of the total - affected. Seven processes are entirely new to the assembly line, such as the installation of the sub-battery in the luggage compartment, the main battery behind the rear seats, the high voltage cable and the modified, 1.8 VVT-i petrol engine.

Quality remains an absolute priority at TMUK and all production techniques were re-evaluated to maintain the highest standards in build quality, durability and reliability.

All assembly line members have received National Vocational Qualification training in the handling of High Voltage components. A new Toyota Vehicle Electric Checking System has been adopted for the rigorous checking of all electrical hybrid components. And a new vision system has been incorporated within the welding process to ensure 100% checking of the high voltage cable and battery fixing weld studs.

The offline inspection area has been completely redesigned to support hybrid assembly requirements, with a specific focus on high voltage componentry and vehicle silent running. A new test track facility allows for comprehensive vehicle road testing, including checking of the Toyota Auris HSD's unique, regenerative braking system.

Based on the five Rs -Refine, Reduce, Re-use, Recycle and Retrieve energy- TMUK's commitment to sustainable manufacturing already has a long history, the Burnaston plant achieving its goal of sending zero waste to landfill back in 2003.

Burnaston is the first car manufacturing plant in the UK to have qualified for Environmental Management System ISO 14001 certification. It has received several awards for its excellent environmental performance and is a carbon positive pioneer.

The experience and knowledge gained by TMUK in the production of the Auris HSD will serve as a foundation for hybrid manufacturing throughout Europe, supporting Toyota's long-term goal of offering hybrid derivatives of all its models by the 2020s.

Grades and equipment levels

The Toyota Auris HSD is available in three grades - Mid, High and Luxury. Its comprehensive standard equipment specification has been carefully considered to simplify and enhance life on board, with electric front and rear windows, folding door mirrors, air conditioning, 7 airbags, front foglamps, LED daytime running lights, alloy wheels, a radio CD player and Hill-start Assist Control fitted as standard across the model range.

The Toyota full hybrid also benefits from wireless, Bluetooth hands-free mobile phone connectivity -independent of the optional navigation system- allowing for incoming call sound output through the vehicle speakers. The fully integrated audio system incorporates a mini jack USB/AUX input terminal located within the upper glove box, allowing for the connection of MP3 players directly to the audio system.

Auto- levelling headlamps can be fitted with optional, High Intensity Discharge (HID) lights, and an optional rear camera with a display integrated into the driver's rear view mirror will be available at a later date.

The Toyota Auris HSD interior incorporates a hybrid-specific driver's instrument cluster and driving mode switchgear and a Shift-by-Wire transmission lever. Instrument and switchgear illumination has been amended to greenish white numbers on a hybrid blue background.

A choice of upholstery finishes features a standard specification, blue-flecked seat panel fabric, while Luxury grade models are trimmed in Alcantara panels with leather surrounds.

HSD Mid

HSD Mid grade models benefit from 15" alloy wheels, automatic air-conditioning, E-CVT electric continuously variable transmission, a Smart Entry and Start system, Vehicle Stability Control plus (VSC+), Hill-start Assist Control, a Push Start button, a blue resin shift-by-wire transmission lever, rear UV reducing privacy glass, a large rear spoiler and dark grey Kaze trim with blue touches.

Grade options include 17" alloy wheels and a 6-speaker Bluetooth CD radio with a microphone and voice recognition.

HSD High

The comprehensive HSD High specification further includes 17" alloy wheels, a 6-speaker Bluetooth CD radio with a microphone and voice recognition, dusk and rain sensors, an EC rear view mirror with back monitor image, a Smart Entry and Start system, cruise control and a large rear spoiler.

Options include full map navigation, rear parking sensors, a sunroof and back monitor image projection on the centre console navigation screen.

HSD Luxury

Providing customers with the ultimate in comfort and convenience, the HSD Luxury grade builds on the HSD High specification with Alcantara seat trim, door trim stitching and a large, hybrid-specific rear spoiler.

Options include High Intensity Discharge (HID) headlamps with washers and an auto-levelling function and a full map navigation system.