Informed speculation: the 7 all-new or updated Toyota and Scion vehicles for 2013

As the calendar turns from 2012 to 2013 and we look back at our previous predictions (some dating back to 2010) on what new or revised models Toyota, Scion and Lexus models were launched, we are reminded that Toyota is a company that is always Moving Forward, even though its new tagline is “Let’s Go Places”. Quite apropos, as buried in the 11 September 2012 news release announcing the new ad and communications tagline was a new round of product predictions. As Toyota Division group vice president and general manager Bill Fay noted,

(We will unveil) seven, exciting all-new or updated Toyota and Scion vehicles in 2013

Longtime Kaizen Factor readers know that we take these proclamations as a challenge to come up with a precise list of the vehicles in question. A couple of things seem crystal-clear: Lexus is specifically excluded from this prediction (their 2013 calendar year new releases are expected to be the 3rd-generation IS sedans, the GX SUV’s mid-life facelift and the new, sub-RX crossover SUV line, the NX); and the fact that it was uttered by a Toyota USA official means no Japanese domestic market or Europe-only models are part of the 7.

Unlike our previous Informed Speculation articles, where we were mostly on our own as far as deducing what went on the lists, this time there is more internet chatter on what the precise models are, mostly via Mark Rechtin of Automotive News. At the 4th-generation Toyota Avalon press preview in early November, he chatted with Toyota U.S.A.’s vice president of marketing Jack Hollis, who revealed that

The Avalon…will be followed by redesigns of the Toyota RAV4 and Highlander crossovers, Tundra full-sized pickup and Corolla compact sedan. A midcycle update for the 4Runner also is planned…

The redesigned RAV4 is expected in the first quarter of 2013; the Highlander and Tundra are coming the second quarter, and the Corolla is scheduled to arrive in the third quarter…

In addition, Toyota’s Scion brand has its xB and xD hatchbacks scheduled for renewals, either as a redesign or an entirely new product category.

Without further ado, here are our predictions:

Toyota Corolla
After the 11th-generation (E160) Corolla’s 2012 calendar year debut in Japan (in sedan, wagon and Auris hatchback guises), Europe and Oceania (Australia/New Zealand), North America patiently waits its turn. And it looks like we may have to wait a bit longer. Once touted as a shoo-in for a 2013 Detroit Auto Show unveiling, the announcement of the Monday 14 January 2013 debut of the Toyota Furia Concept at the show turned that notion on its head. The final scene (shot above right) of its pyromaniac’s delight teaser video shows the side profile of what appears to be a C-segment front-wheel-drive sedan such as the Corolla. And, indeed, there is near-unanimity among pundits (this author included) that Furia is a preview of the 2014 Corolla sedan for North America. Thus, we’d be surprised if the production version of the newest 11th-gen Corolla iteration is officially revealed any earlier than the 2013 New York Auto Show press conferences on Wednesday 27 and Thursday 28 March.

As with most if not all recent Toyota and Lexus new-generation launches, we expect the new Corolla to use a carryover engine from its predecessor, in this case the 2ZR-FE 1.8 liter, 4-cylinder engine. If Oceania’s new Corolla Hatchback (Auris) is anything to go by, it may receive a slight 4 hp bump, to 136. Transaxles, though, may be a different story. Again referencing Oceania and other markets that have seen the newest Corolla, the current woefully obsolete 5-speed manual and 4-speed automatic will, in all likelihood, be replaced by a 6-speed manual and a Multidrive CVT (Continuously Variable Transmission). Yes, it’s more likely than not that the Corolla will become the second non-hybrid (besides the Scion iQ) Toyota CVT application in North America. Whether any of them (such as a sporty Corolla model) will use the Multidrive S with 7-speed sport sequential manumatic mode and paddle shifters remains to be seen.

Speaking of sporty Corolla models, we hope the current tepid Corolla S model gives way to a proper Corolla SE that follows the lead of current Yaris, Camry and Sienna SE variants in going beyond the merely cosmetic and offering meaningful firmer suspension and steering tweaks. And what about a return of the Corolla XRS with the 2.5-liter, 4-cylinder 2AR-FE engine as a rival to the Honda Civic Si, Ford Focus ST and Volkswagen GTI? Don’t count on it, much as we’d like to see it. Another losing bet is on a third generation of the Toyota Matrix, as Toyota Division group vice president and general manager Bill Fay told Mark Rechtin of Automotive News, “If we don’t have the Matrix, it won’t be the end of the world.” Thus, it seems that the Toyota brand will join the Chevrolet Cruze, Dodge Dart, Honda Civic and Nissan Sentra in not offering a C-segment 5-door hatchback body style in the United States. No biggie, for the Scion brand will probably take up the slack. More baffling is Fay’s contention that the Matrix will continue to be available in Canada. Will the aging 2nd-generation E140 Matrix soldier on alongside the newer E160 Corolla sedan in the Great White North? Or might the Green Car Reports‘ John Voelcker be on to something when he suggests that the new E160 Auris might be imported into Canada as a Matrix replacement?

Toyota Highlander
With Toyota’s Camry and Avalon and the Lexus ES having been renewed within the past year or so, it is now their K-platform Highlander sibling’s turn for a new generation. Although any growth spurt would probably be slight, at least the discontinuation of the V6 and 3rd-seat options from the North American RAV4 makes for much less overlap between the two. The 3.5-liter 2GR-FE V6 should be largely carryover. Whether the base 2.7-liter 4-cylinder 1AR-FE engine survives in the next Highlander is an open question, given that in the latest Sienna minivan the 4-cylinder option was a barely more fuel economical resounding flop that was only offered for 2 model years. For the V6, it is a given that the current 5-speed automatic transaxle will give way to the U660E 6-speed auto currently used in the latest Camry, Avalon and ES V6s.

The current 2nd-generation Highlander is an anomaly that, like the Toyota Zelas/Scion tC and Lexus ES, is built (as a hybrid and for export to a handful of markets outside North America) but not sold in Japan. Going forward, however, that will change. As a February 2012 press release informs us:

Toyota will increase production of the Highlander mid-size SUV in late 2013 at the company’s Princeton, Indiana (USA) plant. Hybrid and export versions will be included…

The company will invest about $400 million to support global demand for the Highlander, which will no longer be built in Japan by late 2013. Toyota builds Highlander in China for that market only…

Highlander is currently sold in Russia and Australia, and TMMI will export to those countries.

Speaking of Australia, in that market the Highlander still bears the horrible, Freddy Kruegeresque Kluger nameplate, due to a conflict with a Highlander trim level for the Hyundai Terracan SUV that was discontinued in 2007. Might the Australian nomenclature finally align with that for the rest of the world?

Given the newest Corolla’s preview by the Furia concept and Jack Hollis’ assertion that the 3rd-generation Highlander will go on sale in the 2nd quarter of 2013, might this be the major production Toyota debut for the 2013 Detroit Auto Show?

Toyota Highlander Hybrid
As noted above, the big news regarding the 3rd-generation of the Toyota Highlander Hybrid is the shift in sourcing from Japan’s Kyushu facility to the Toyota Motor Manufacturing Indiana, Inc. (TMMI) plant in the U.S. This makes it the first Toyota hybrid to be built in the Hoosier state.

We suspect that the 2.5-liter, 4-cylinder 2AR-FXE hybrid gasoline-electric powertrain from the current Camry, Avalon and Lexus ES would be marginal in the bulkier and heavier Highlander, but would an extra 178cc, 8 hp and 15 lb/ft of torque make the difference? Those are the approximate benefits from hybridizing the current base Highlander’s slightly larger 1AR-FE 2.7-liter four to create an Atkinson cycle hybrid 1AR-FXE. Useful as they may be, though, we suspect that the next Highlander Hybrid will carry on with the current 2GR-FXE 3.5-liter V6 hybrid powertrain.

Given all this emphasis on U.S.-only sourcing, we expect the latest Highlander to join the Avalon and RAV4 EV in having an American chief engineer.

Toyota Tundra
The current, 2nd-generation of the space shuttle-towing Toyota Tundra full-size pickup truck made its debut at the February 2006 Chicago Auto Show. Since then, it has seen a minor facelift coupled with the replacement of the “middle option” 4.7-liter 2UZ-FE V8 engine with the newer, more powerful yet more economical 4.6-liter 1UR-FE V8 for the 2010 model year. We expect its latest version to debut 7 years later, during the Thursday 7 and Friday 8 February media preview for the 2013 Chicago Auto Show.

By most accounts, don’t expect a totally new, 3rd-gen Tundra to emerge. Rather, we should expect to see something akin to the extensive second facelifts applied to the 3rd-generation (XX30) Toyota Avalon in April 2010 for the 2011 model year; or to the 4th-generation (XF40) Lexus LS for the 2013 model year. Or, in the words of Motor Trend

…a source confirmed to us that the Tundra’s updates will be purely aesthetic and quite minimal – don’t expect to see any updates to the truck’s powertrains.

This is partially contradicted by Mark Rechtin of Automotive News‘ predictions dating back to last August:

Toyota will call (the spring 2013 re-engineering) a full redesign, but the V8 powertrains and suspension will remain the same, and the ladder frame dimensions won’t change much…

Expect Toyota to start pushing the 4.0-liter V6 version hard for corporate average fuel economy reasons, using direct injection to boost horsepower from its current 270 to more than 300. A larger fuel tank will increase range. Expect more “trucky” styling.

Finally! A long-overdue 1GR-FSE direct-injected 4-liter V6. We wonder if it will feature dual (D4-S) direct+port injection or go direct injection-only like the 2.5-liter 4GR-FSE V6. And would a V6 that powerful threaten to make the small 4.6-liter V8 redundant?

In comparison to the recent activity surrounding Detroit 3 full-size pickup trucks, then, expect something more akin to the 2013 Ford F-150 and Ram 1500 refreshes than an all-new generation like the upcoming 2014 Chevrolet Silverado and GMC Sierra.

Toyota 4Runner
The 5th-generation 4Runner was unveiled at the Texas State Fair on 24 September 2009, for the 2010 model year. Thus, it is due for a mid-life refresh for the traditional autumn 2013 kickoff of the 2014 model year. Primarily focused around new headlights, taillights, front grille inserts, exterior colors and interior tweaks, there may nevertheless be one significant change if Mark Rechtin’s Tundra prediction noted above holds true: the addition of direct (or dual direct+port) injection to the current 4-liter 1GR-FE V6 to create a 1GR-FSE successor.

Its overseas Toyota Land Cruiser Prado fraternal twin and its upmarket Lexus GX 460 derivative should similarly see a minor facelift, the latter becoming the latest Lexus to receive the signature spindle grille.

Toyota Sequoia
Where the Toyota Tundra goes, its Sequoia full size sport utility vehicle offshoot soon follows. Although not explicitly mentioned in the latest round of “new Toyota” predictions, the suggestion of a 2014 model year “re-engineering” by Rechtin would imply a Tundra-like makeover to appear no later than the 2013 Los Angeles Auto Show press previews on Wednesday 20 and Thursday 21 November. For reference, the 2nd-generation Tundra made its public debut at the February 2006 Chicago Auto Show but did not go into production until a full year later, on February 2007. In contrast, the 2nd-gen Sequoia first appeared at the November 2007 Los Angeles Auto Show but went into production the following month. Thus, our prediction is not particularly far-fetched.

Given that the Sequoia is probably too large and heavy for even an upgraded 1GR-FSE V6, don’t expect much more than a revised front end, taillights and wheels, with a couple of new exterior colors and some interior tweaks thrown in for good measure.

New Scion hatchback (xD successor?)
Historically, Scion’s two 5-door hatchback offerings have marched together in lockstep. The original 2004 xA and xB debuted at the Los Angeles Auto Show on 2 January 2003 and both went on sale together, starting with 105 Toyota dealerships in California on 6 June of that year. Their successors, the xD and the 2nd-generation xB were both unveiled on 16 December 2006 at an invitation-only, no-camera event in Miami, Florida, followed by their joint public reveal on 8 February 2007 at the Chicago Auto Show. Soon thereafter, however, each went their own way. The xD went on sale in early August 2007 and soon settled into a routine groove of traditional late summer/early fall (between August and October) annual model changes. In contrast, the larger 2nd-gen xB was all over the map…er…calendar when transitioning from one model year to the next. After its debut in early May 2007 (3 months ahead of its xD sibling), it followed a March/April pattern for release of the following model years until 2011, when the 2012 xB was pushed back to July (thus creating a 16-month 2011 model year). Another 16-month (if not even longer) 2012 model year is in store, given that the 2013 model year xB, in Scion’s words, “will begin arriving in dealerships early next year” (the 2013 calendar year).

In light of this, we’re going to agree to disagree with Mark Rechtin’s contention that replacements for both the xB and xD will be introduced at the New York Auto Show in March. Would Scion really replace the xB so soon after the 2013 model goes on sale? We’ll stick out our necks and say no, and suggest that Scion’s 10th-anniversary festivities will only include a single new model, and that the xD will be discontinued before the xB. We will agree, though, that we’ll likely see several new Release Series special editions during 2013 to celebrate 10 years of Scion. (This author will be rooting for an admittedly unlikely long-shot larger-engined, manual transmission Scion iQ micro-hot hatch).

Toyota’s traditional veil of secrecy becomes even more impenetrable when trying to figure out what the future holds for the Scion model range. Back in April, a teaser for a subscriber-only WardsAuto article quoted then-Scion vice president Jack Hollis as saying

We don’t have plans for a direct xB or xD replacement…Harkening back to the original brand tenet of “one-and-done” models, Scion won’t carry over the names of the xB and xD

Soon, the notion of rebadged Daihatsu models as part of the future of Scion took hold, and Mark Rechtin, in the latest iteration of his annual “future of Scion” predictions for Automotive News and AutoWeek agreed, suggesting that

There has been talk of reconfiguring the boxy, 100-inch wheelbase Daihatsu COO/Materia (a.k.a. Toyota bB), which is closer in size and design to the original xB that defined the Scion brand.

Because of the xD’s tepid sales, Scion is rethinking its entry in the segment. We may see something more like the Ractis mini-minivan from the Japan market. The new xD (successor) likely will arrive in the fall of 2013.

Other possibilities
In spite of having more clues and hints than ever, there is still an unexpected level of uncertainty hanging over these predictions. Does the Toyota RAV4, with a public reveal in November 2012 but an early 2013 start-of-manufacture and sales date truly belong on last year’s predictions list or on this one? Is Mark Rechtin right about 2 Scion debuts for 2013 versus our prediction for a single one? Is Toyota counting the Highlander as one entity this year as opposed to last year’s counting of hybrids and non-hybrid versions separately?

Speaking of hybrids, a number of pundits, such as Auto Express, Green Car Reports and WardsAuto have wondered about the possibility of a gasoline-electric RAV4. Auto Express quotes RAV4 Deputy Chief Engineer Yoshikazu Saeki as saying that

…a hybrid “would not be difficult to do. We are watching the market. After introducing the new RAV4 we will see. There will be a possibility of introducing a hybrid RAV4 and we will respond to what the market wants.”

while WardsAuto cites Toyota U.S.A vice president-marketing Bill Fay as saying that

A hybrid version of the RAV4 is possible, but not now. You never know what’s down the road, but nothing short-term.

Perhaps Toyota sees some overlap between the Prius v and a RAV4 Hybrid, even though the former is longer, lower and narrower than the new RAV4. Also, unlike RAV4, Prius v is unavailable with all-wheel-drive. Or is Toyota, in a sense, borrowing from the Ford playbook that saw it abandon the Escape crossover SUV hybrid in favor of a front-wheel-drive only C-Max Hybrid tall wagon?

The initial draft of this article had a 2014 model year mid-term facelift for the 3rd-generation Toyota Sienna not-so-minivan in place of the Sequoia, given that the outgoing Highlander got one after 3 model years. The current Toyota Venza, Tundra and 4Runner mid-life refreshes, on the other hand, didn’t happen until after the 4th model year, Thus, we walked away from that prediction.

Finally, my esteemed colleague Flipside909 keeps insisting on how long overdue the Tacoma not-so-compact pickup truck is for a new generation. To which Mark Rechtin (again?!) of Automotive News replies:

The Tacoma soldiers on until a fall 2014 redesign that is required for safety and emissions standards.

Ahhh…then we can start our 2014 calendar year predictions list with a Sienna facelift and a new-generation Tacoma…

TMC’s Environmental Technology Development update: a peek at Toyota and Lexus’ powertrain future (Part 1)

On Monday 24 September, what was ostensibly the press preview for the (very limited) production version of the battery electric variant of the Toyota iQ soon became, in the words of Bertel Schmitt of The Truth About Cars, “the strangest product launch I have ever seen”. Given how much information the usually reticent Toyota revealed regarding its future powertrain plans, press coverage was equally strange, veering between overly simplistic and sensationalist sound bites. Toyota to Launch 21 New Hybrids and a New Fuel Cell Vehicle in the Next Three Years! Toyota drops plan for widespread sales of electric car! Toyota kills electric car plans, says ‘capabilities of electric vehicles do not meet society’s needs’! Ultimately, only a trio of accounts of what transpired at the Universal Design Showcase of Tokyo’s MegaWeb are truly worth reading: the aforementioned Bertel Schmitt of The Truth About Cars‘ “you-are-there” report, Hans Greimel’s Automotive News/Autoweek story for its large number of exclusive tidbits of information and, if you’re really pressed for time, Jake Holmes of Motor Trend‘s summary of the full TMC Announces Status of Its Environmental Technology Development, Future Plans Toyota Global newsroom PDF document. If, however, you prefer deep-dive analysis, commentary, interpretation and informed speculation of the sort Kaizen Factor thrives on, stay with us as we deconstruct Toyota’s newest revelations.

A new 2AR-FXE with D-4S engine variant
The “enhanced engine for use in hybrid vehicles, based on the 2.5-liter AR gasoline engine, (adopting) the Atkinson cycle and D-4S system” is none other than a new D-4S (dual direct+port injection) variant of the 2AR-FXE 2.5-liter 4-cylinder Atkinson cycle hybrid engine used on the current Toyota Camry Hybrid and Lexus ES 300h. The existence of this engine was actually revealed a week earlier, in a Lexus USA Newsroom press release for the Lexus LF-CC concept. In a story for the my.IS website, yours truly figured that it would produce something in the vicinity of 220-225 total system horsepower (versus 200 total system horsepower for the port injection-only 2AR-FXE). Toyota’s Environmental Technology Development news release adds a couple of new bits of information. For one, the 2AR-FXE with D-4S achieves the world’s highest maximum thermal efficiency (38.5%), which translates into the engine producing more power and using less fuel, while wasting less heat.

Hans Greimel also informs us that this iteration of the 2AR-FXE engine will receive Denso’s newly-tweaked D-4S injectors that already appear in the 4th-generation Lexus GS and Scion FR-S/Toyota GT 86. In comparison to the original D-4S injectors that date back to 2006, the new ones use a slit-shaped (as opposed to the previous multihole) injector opening. This creates a richer fuel mixture inside the cylinder and results in 1% better fuel economy.

Toyota reveals that this engine will go on sale sometime during calendar year 2013 in an undisclosed vehicle. Greimel, however, suggests that the Japanese domestic market’s Toyota Crown Hybrid will be the first recipient of the new powerplant. Makes sense, as this would allow for some closer-to-home experience before exporting it in the Crown’s platform-mates, the rumored (and trademarked) Lexus GS 300h and IS 300h versions of the 4th-gen GS and 3rd-gen IS, respectively. Given current rumors that the IS 300h, like the outgoing IS 200d and IS 220d, will only be sold in Europe, expect a debut for the Lexus variants at either the 2013 Geneva Motor Show (press previews on Tuesday 5 and Wednesday 6 March) or, later in the year, at the Frankfurt Motor Show (press previews on Tuesday 10 and Wednesday 11 September).

Beyond its initial applications in Toyota’s new rear-wheel-drive N-platform (launched with the 4th-generation Lexus GS and expected to spread to the upcoming 3rd-generation Lexus IS and 14th-generation [S210 or S220] Toyota Crown), will the 2AR-FXE with D-4S hybrid powertrain eventually migrate to the myriad front-wheel-drive K-platform Toyota Camry derivatives that use the AR 4-cylinder engines? Could be…

A turbocharged 3AR-FTE or (better yet) 3AR-GTE?!
In what is perhaps the biggest surprise of the Environmental Technology Development announcement, Toyota informs us that

Starting 2014, TMC plans to launch a vehicle with a new 2.0-liter, turbo-charged AR engine, also based on the 2.5-liter AR gasoline engine. The new engine’s smaller displacement will provide higher fuel efficiency while the turbocharger will improve output.

In other words, Toyota is meeting the challenge laid down by Volkswagen, General Motors, Ford and Chrysler/Fiat, among others, in going the smaller displacement with a turbo route, all the better to “game” the U.S. EPA fuel economy cycle (and its European and Japanese counterparts) into producing lower consumption numbers realistically achievable only if you drive 24/7 like Grandma on a day she forgot to eat her breakfast. Step on it, spool the turbo up to full boost, and you’ll use more gas than in the naturally-aspirated 2.5, but I digress…

As we noted back in December 2011,

When looking back at Toyota’s boosted gasoline powerplants, the company’s history is akin to Audi’s, with a mix of turbocharging (Supra, 2nd-generation MR2, Toyota Celica All-Trac Turbo/GT-Four) and supercharging (1st-generation MR2, TRD aftermarket kits and Australia’s Aurion TRD). The new millennium, however, has seen nothing but superchargers.

Thus, it’s a 180 degree, back-to-the-future turn for Toyota to turbocharge, as opposed to supercharging, its AR 4-cylinder engine.

Deducing what engine code the new 2-liter AR turbo will use is a fairly straightforward matter. As is the case for Toyota and Lexus’ GR V6 engine family, the smaller the first number, the larger the engine displacement, and vice-versa. The 1AR-FE is a 2.7-liter 4-cylinder engine that debuted in Toyota’s current Venza and Highlander, made a brief appearance in the current Sienna minivan and is also available in the Asian-market Lexus RX 270. The 2AR-FE is its smaller 2.5-liter variant (shown above left) that is available in Toyota’s RAV4 and Camry, the Scion tC coupe and the new throwback-badged Lexus ES 250 for the Chinese market. The 2AR-FXE, of course, is the hybrid version we discussed earlier. Thus, a 2-liter version will be a 3AR. The “F”, per Wikipedia, denotes an economy narrow-angle valve DOHC (dual overhead camshaft) head, while a “G” would make it a performance wide-angle valve DOHC. A “T” for turbo is, of course, obligatory, as is the final “E” for electronic fuel injection. Thus, it would be a 3AR-FTE if it’s more economy-oriented or a 3AR-GTE if it’s performance-oriented. Sure, we definitely prefer the latter, but should also note Toyota GT 86 chief engineer Tetsuya Tada’s thoughts on boost (again from our December 2011 article):

Tada-san favours the supercharger approach because it is simpler to achieve than increasing engine size and doesn’t wreck throttle response as turbocharging might. Indeed Toyota says that turbocharging along with four-wheel drive and wide tyres are what make sports cars boring to drive.

In other words, we suspect a more economy-oriented 3AR-FTE is likelier. As to what 2014 vehicle gets the honors of launching this engine, it’s anybody’s guess, but this author suspects some sort of obscure, low-production variant of the Corolla for the Japanese domestic market. I know our co-editor Flipside909 is rooting for it to power a Volkswagen GTI-rivaling son-of-Corolla FX16 GT-S. Or, perhaps, a non-hybrid Lexus CT 200t sporty hatchback with a proper manual transmission?

Another compelling question is whether or not the so-called 3AR-FTE will use D-4S dual direct+port injection. We suspect not, given the historical issues with aftermarket boost for Toyota’s GR-FSE V6s and how Subaru went direct injection-only when turbocharging the FA20 flat 4.

Toyota’s small ND diesel gets a reprieve for Europe
In our first article on the BMW/Toyota alliance, we figured that Toyota wouldn’t bother to reengineer its aging diesel engines to meet upcoming Euro 6 standards. It turns out we were wrong, at least insofar as the smallest of them all, the 1.4-liter 1ND-TV. As the carmaker informs us,

The adoption of newly developed exhaust gas cleaning technology enabled the engine to pass the Euro 6, one of the most stringent exhaust emission standards in the world. Vehicles equipped with the new diesel engine are planned for launch starting 2015.

Thus, expect the 1ND-TV to soldier on in Toyota’s Yaris, Auris, Corolla, iQ, Ractis/Verso-S and Urban Cruiser (Toyota ist/Scion xD) lines, as well as in India-built versions of the Etios and Etios Liva models. On the other hand, the press release is silent on the ultimate fate of Toyota’s medium-sized AD 4-cylinder diesels. Expect those to be replaced by BMW diesels as of 2014.

i-ART: another Toyota/Denso fuel injection breakthrough
Throughout this article, D-4S, the first-ever dual direct+port injection system pioneered by Toyota and automotive supplier Denso, has been a recurring theme. Flying under the radar, however, the latter (itself a member of the Toyota Group conglomerate) announced, in December 2011, the creation of i-ART (intelligent-Accuracy Refinement Technology) the world’s first autonomous closed-loop diesel fuel injection control system. In essence, this system equips each injector with a pressure sensor that communicates its fuel pressure to the engine ECU and, in doing so, significantly reduces exhaust emissions and increases fuel efficiency, compared with the conventional open-looped technology that does not have feedback function from the injectors. i-ART-equipped versions of the 3-liter 1KD-FTV 4-cylinder diesel debuted in the Brazilian market version of the Hilux pickup truck in April 2012. Given the ease with which a 2-liter diesel i-ART test unit met upcoming Euro 6 emisions standards, we wouldn’t be surprised if this technology spread throughout the KD diesel engine family (including the smaller 2.5-liter 2KD-FTV) and to other Toyota truck-based lines such as Land Cruiser Prado and Third World models such as Fortuner, Innova and Hiace. And, if this technology is so emissions-friendly, wouldn’t it be cool to see these diesels in North America’s expansive truck-based Toyota line, not to mention in Lexus’ GX as a rival to the German luxury diesel SUVs? Then again, 3 liters is awfully large for a 4-cylinder engine, and the Germans use 6 cylinder diesels in this size segment, at least in North America, so the KD might be a bit crude for Lexus duty…

Arrghh! Toyota’s CVTs spread beyond hybrids, Europe and Japan
As Toyota’s Environmental Technology Development update shifts its focus from engines to transmissions, discussion begins with one of this author’s pet peeves: CVTs, or continuously variable transmissions. I’m still regretting the way in which the traditional manual transmission with a clutch pedal is becoming a dinosaur of an endangered species, but at least modern torque-converter automatic transmissions and so-called single and dual-clutch (but no clutch pedal) transmissions purport to maintain some level of driver control via “manumatic” modes, gates and paddle shifters. CVTs, on the other hand, are far less likely to offer these options. As of now, dissatisfaction with the “manual mode” paddle shift feel on the Lexus CT 200h’s CVT transaxle led to a decision to limit this option to the Japanese domestic market. Indeed, the so-called “rubber band feel” of CVTs and the way they hold high revs while the car barely seems to move is off-putting to many.

Yet, CVTs also have their virtues, fuel efficiency chief among them. They are also the best way to manage hybrid powertrains, as tepid reviews of hybrids with torque-converter automatics such as the Infiniti M and the Hyundai Sonata/Kia Optima fraternal twins can attest to. At any rate, a number of carmakers, such as Nissan and Subaru have staked their future on the CVT, and Honda and Audi also use them on some models. We certainly hold out hope that diligent engineering will result in future CVTs that…er…don’t suck, as Nissan seems determined to do.

Perhaps we’re dismissive because, in North America, the Scion iQ is the sole non-hybrid Toyota product using a CVT, whereas Japan and Europe offer a plethora of CVT-equipped models. In the latter market, so-called Multidrive (M/D) and paddle shifter-equipped Multidrive S (M/D S) models use the CVT. These, by the way, should not be confused with Multimode Manual Transmission (M/M) models that use a type of sequential manual transmission consisting of a traditional manual gearbox with an electronically controlled clutch (but no clutch pedal). The Environmental Technology Development press release touts

TMC’s newly developed continuously variable transmission, Super CVT-i, (that) has achieved both superior fuel efficiency and smooth acceleration due to its unsurpassed transmission efficiency, improved integrated engine control and reductions in both size and weight. The transmission, first installed on the Corolla for the Japanese market in June 2012, is planned for use on additional models, particularly in the compact segment.

Perhaps those additional models include the upcoming North American version of the 11th-generation (E160) Toyota Corolla.

From the folks that brought you the world’s first 8-speed automatic transmission, the world’s first 8-speed automatic transaxle
Back in 2006, Japan’s automatic transmission manufacturer Aisin AW rocked an automotive world accustomed to 4, 5 and 6-speed automatics by designing the TL-80SN, the first-ever 8-speed automatic transmission. Suitable for rear-wheel-drive applications, it debuted in the 2007 XF40 (4th-generation) Lexus LS 460. The AA80E transmission, as Toyota calls it, soon spread through their V8 car lineup, namely the Lexus IS F, the late, lamented Lexus GS 460 and the Toyota Crown Majesta. Nearly 2 years later, German automotive supplier ZF countered with its own 8-speed longitudinal automatic transmission, the 8HP. After launching with the 5th-generation (F01/F02) BMW 7-Series, the 8HP quickly spread to other brands such as Audi, Bentley, Chrysler, Jaguar, Land Rover and Rolls-Royce. Hyundai, meanwhile, developed its own 8-speed automatic for use in the Genesis and Equus lines.

Notice, though, that even the highly flexible ZF 8HP unit is a longitudinal transmission, used by Audi only in its longitudinally-engined lines (A4 thru A8), and not in its smaller (A3 and below, plus TT) transverse-engine models. Leave it, again, to Toyota and Aisin to follow up the pioneering TL-80SN / AA80E with the world’s first transversely-mounted 8-speed automatic transaxle, the U880F which premiered on the all-wheel-drive Lexus RX 350 F Sport SUV for the North American market in August 2012. And, stay tuned, for Toyota strongly hints that the U880, presumably in “regular” (front-wheel-drive) and F (AWD) iterations, should eventually spread throughout Lexus and Toyota’s FWD-centric models.

21 new hybrid models between now and the end of 2015
Among the numerous revelations contained in Toyota’s Environmental Technology Development update, the claim you see above is among those that has been most widely reported and generated the most buzz. Yet, to our knowledge, no one has attempted to name the 21 vehicles. And, frankly, we’re not about to either, at least not in the in-depth manner in which we dared to guess at the 7 all-new hybrids, 4 revised existing hybrids and 19 new or revised models for North America due by the end of calendar year 2012. The nearly 3½-year time frame and the global (including Lexus) nature of this list makes even Kaizen Factor‘s crystal ball go all blurry and erratic. Further confusing things is what Toyota means by “now”. The Monday 24 September 2012 date of Toyota’s Environmental Technology Development update? Or the August 2012 date mentioned in a couple of Toyota’s footnotes? This seemingly picayune point is key in determining whether or not the Lexus ES 300h, which went on sale in the United States and Canada during August 2012, is part of the list of 21.

Hans Greimel of Automotive News did note, however, that 14 will be either all-new nameplates or hybrid versions of vehicles that don’t currently come with an electric-gasoline option, leaving 7 next-generation, or full-model changes to existing hybrids. The latter are easier to guess at, and we figure that next-generation hybrid versions of Toyota Auris, Toyota Prius, Toyota Highlander, Toyota Estima (a primarily Japanese domestic market minivan that is a bit smaller than the Sienna), Toyota Crown, Lexus RX and Lexus LS are the likeliest 7.

And what about the 14 all-new nameplates or hybrid versions of vehicles that don’t currently offer an electric-gasoline option? These run the gamut from the obvious (The Toyota Avalon which will go on sale by the end of 2012 and the trademarked Lexus IS 300h) to the safe bet guesses to the flat-out speculative. And, speaking of Lexus, do rumored additional, alternate-engined versions of existing hybrids (think Lexus CT 300h, Lexus GS 300h or Lexus LS 450h) count separately among the 21?

Our previous Informed Speculation articles suggested hybrid versions of Toyota Avensis, Toyota Sienna, Toyota RAV4 and, perhaps, Toyota Venza. With the 11th-generation (E160) Corolla already available in Japan in a couple of variants and its Auris offshoot already hybridized, don’t be surprised if a Toyota Corolla hybrid becomes available. Don’t expect, however, a future version, hybrid or otherwise of the Toyota Matrix, which will die at the end of the 2013 model year.

Talk of a potential RAV4 hybrid reminds us that its upcoming 4th-generation (XA40) is expected to sire a Lexus sibling, which could wear the Lexus TX 300h moniker. And might the brand’s two recent hybrid concept coupes – LF-CC and LF-LC – lead to production versions bearing, say, Lexus IC 300h and Lexus LC 600h badges?

And what about the Toyota/Ford collaboration on a “new co-developed hybrid system ready for use later this decade on…rear-wheel-drive light trucks and SUVs”? Does that mean we’ll see hybrid Toyota Tundra and Toyota Sequoia models by the end of 2015? Hard to say, since the original Toyota Global and USA news releases from 22 August 2011 not only fail to mention any prospective production dates but promised to move from Memorandum of Understanding to formal production agreement “by next year” – meaning 2012 – yet, with less than 3 months to go before year’s end, nothing has happened. Might an announcement be forthcoming at the 2012 Los Angeles Auto Show press conferences on Wednesday 28 or Thursday 29 November?

Finally, Lord knows what obscure Japanese domestic market-only hybrids Toyota will come up with. For example, this author vaguely recalls reading something about possible hybrid versions of the oddball, asymmetrical door (single slider on the left, two regular doors on the right) Toyota Porte/Spade twins. Not much of a stretch, really, since they share their underpinnings (read NBC, or New Basic Car platform) with Yaris and Prius c/Aqua.

Thus ends Part 1 of our in-depth analysis and commentary on Toyota’s Environmental Technology Development update, which corresponds to the Initiatives for Energy Conservation section of the news release, focusing on improvements to conventional gasoline, diesel and hybrid powertrains. Stay tuned for Part 2, which will feature our thoughts on Initiatives for Fuel Diversification, as Toyota describes various degrees of electrification such as plug-in hybrids, battery electric vehicles and fuel cells. This will conclude with a Beyond the News Release section featuring additional background information, much of it from journalists that attended the actual press event in Japan.

From earthquakes and a tsunami to…tornadoes!? *UPDATED*

Lately, it seems that Toyota can’t catch a break from Mother Nature’s wrath and fury. We’ve certainly been diligent in reporting on the aftermath of the Great East Japan Earthquake and the tsunami and aftershocks that followed, and now, half a world away, another Toyota facility is down but not out because of a natural disaster. A swath of tornadoes that hit the southeastern United States on Wednesday 27 April and winds that reached speeds of 200 mph (322 kph) struck particularly hard in the Tuscaloosa, Alabama area that is the home of a number of foreign carmakers’ U.S. assembly facilities. With major U.S. news outlets such as the Associated Press, Reuters and Bloomberg rightfully focused on general news from the impacted areas, it is trade paper Automotive News that brought us an initial and follow-up report on the aftermath of the tornadoes insofar as carmaking facilities. The tornadoes that claimed at least 339 lives across seven states, including at least 248 in Alabama, caused no direct damage to Hyundai’s plant in Montgomery (well south of the Tuscaloosa area) nor to Honda’s facility in Lincoln (in the eastern part of the state). Mercedes-Benz’s plant in Vance, just north of Tuscaloosa, ultimately suffered just minor siding and roof damage, and with electric power on in that area, the company has announced that production of GL, M, and R class SUVs and crossovers will resume on Monday 2 May.

Slightly more affected is the engine-making Toyota Motor Manufacturing, Alabama (TMMAL) facility in Huntsville that currently assembles 4-liter 1GR-FE V6 as well as 4.6-liter 1UR-FE and 5.7-liter 3UR-FE V8 engines for Toyota’s Tundra and Tacoma pickups and Sequoia SUV. While the plant itself saw minimal damage, the tornadoes ripped down utility lines in the vicinity and, as of Friday 29 April, the TMMAL facility remained without power. This may be a moot point for now, however, given Toyota’s current no-production-on-Mondays schedule in the aftermath of the Japanese natural disasters. As in Japan, though, it remains to be seen how local automotive parts suppliers have been affected, although early reports cite, at worst, a Toyota-like situation of minimal-to-no-damage with a lack of electric power.

Although Alabama’s travails appear to be notably less severe than Japan’s, we can’t help but wonder if the plan to start assembly at the TMMAL facility of 2.5-liter 2AR-FE and 2.7-liter 1AR-FE 4-cylinder engines (as found in Toyota Camry, RAV4, Scion tC and Toyota Highlander, Venza and Sienna) by summer 2011 (as noted in Toyota’s USA and Global Newsrooms) has been pushed back. As an aside, we’d like to note that the Alabama engine plant is the only facility outside Japan that builds Toyota V8 engines.

Photo Credit: CBS News

Saturday 7 May UPDATE:

The Toyota USA Newsroom informed us on Thursday 5 May that Toyota will make a $1 million contribution to the American Red Cross to support relief efforts for victims of the recent outbreak of tornados in the Southern, Midwestern and Eastern regions of the United States. In addition, Toyota will match employee contributions to the American Red Cross. The company will also provide additional support and assistance to those Toyota employees who have lost their homes.

Informed Speculation: The 7 new Toyota and Lexus hybrids due by the end of 2012

Coinciding with the public debut at the 2010 Los Angeles Auto Show of the Toyota RAV4 EV Demonstration Vehicle jointly developed by Toyota and Tesla, a press release in the Toyota USA Newsroom ends with this sentence: “Finally, by the end of 2012, Toyota will add seven all new (not next-generation) hybrid models to its portfolio”. Just what, precisely, are those seven vehicles? Toyota, naturally, isn’t saying at this point. But that never stopped a future product-obsessed übercargeek like yours truly from indulging in some intelligent guesswork and informed speculation on what those might be.

First, though, some ground rules. The aforementioned sentence in the Toyota USA Newsroom’s RAV4 EV press release is preceded by this passage: “Toyota has announced that coinciding with the arrival of the RAV4 EV in 2012 it will launch, in key global markets, the Prius PHV (plug-in hybrid) and a small EV commuter vehicle. It will also launch, in key global markets, its first commercialized hydrogen fuel cell vehicle in calendar year 2015, or sooner.” Thus, it is obvious that those vehicles are specificaly excluded from the seven all-new hybrids in question. Also, the “all new (not next-generation) hybrid” qualifier specifically excludes the hybrid variants of the 4th-generation Lexus GS and 7th-generation Toyota Camry that are due out within that time frame, given that their immediate predecessors already offer hybrid versons. Finally, the wording of that passage seems to allow room for Lexus-branded vehicles as well as for hybrid models that won’t be offered in North America but will be available in Japan and/or Europe. Here, then, is a listing, in no particular order, of what this Kaizen Factor author believes will be the seven all-new and unprecedented hybrids that will be released by the end of calendar year 2012 (thus allowing for a 2013 model year designation):

Toyota Prius MPV (also referred to as Prius Alpha or Prius Verso)
This is the first and most obvious of the seven new hybrids to be released. Already teased at the 10 Years of Prius Anniversary Celebration that took place on 10.10.10 in Malibu, California via the “Prius Puzzle” that was the subject of a YouTube video whose final shot appears above, it is widely expected to debut at the 2011 Detroit Auto Show on 10 or 11 January 2011. That photo implies that this new, taller Prius may well draw its inspiration from 2007’s Hybrid-X concept. At any rate, this is predicted to be a 3-row seating mini-minivan to rival the Mazda5 in North America and a plethora of such vehicles available in Europe.

Most pundits (this author included) believe that it will be powered by yet another application of the 2ZR-FXE 1.8-liter 4-cylinder powertrain from the 3rd-generation Toyota Prius, Toyota Auris HSD and Lexus CT 200h, albeit tweaked for a bit more power (some reports state 138 hp combined, versus the 134 hp of the aforementioned models). On the other hand, Road & Track‘s Nick Kurczewski states that this may be the vehicle to debut the long-overdue hybrid powertrain based on the 2AR-FE 2.5-liter 4-cylinder engine from the latest Toyota Camry, RAV4 and Scion tC, possibly (but not likely) featuring a lithium-ion battery pack versus the current nickel-metal hydride batteries.

As to the precise model name, MPV is (Mazda’s use of the initials as a model name notwithstanding) an abbreviation for multi-purpose vehicle, the generic European name for a tall 2 or 3-row seating 5-door hatchback. A mini-minivan, in other words and, as such, unlikely to be used by Toyota. Prius Alpha, though reportedly the name according to several news outlets, is probably a nonstarter as well, given the potential for confusion with Alfa Romeo. Prius Verso is the likeliest name, given that Toyota has in the past used the Verso badge to denote MPV derivatives of the Yaris, Corolla and Avensis. Current policy of making Verso (and Verso-S) stand-alone badges in Europe may work against this, though, as well as potential confusion between Venza and Verso in North America.

Also pictured below is a teaser shot, posted on Facebook, of the “Prius MPV”‘s instrument panel center stack.

“Baby Prius”, based on Toyota FT-CH concept
Generally touted as the predictor for the third and smallest member of the Prius family, Toyota unveiled the FT-CH concept at the 2010 Detroit Auto Show. Although stating that its overall length of 153″ (3895mm) is 22″ shorter than the current Prius 5-door while almost matching the larger car’s 68.7″ width, Toyota has been notably coy about revealing its wheelbase. Both Autoguide.com and Consumer Reports, however, claim the magic number is 100″ (2550mm), or spot-on the Yaris 4-door sedan’s wheelbase. Frankly, this doesn’t really say much on whether the baby Prius will be based on a cut-down version of the Prius’ MC architecture or on the longer version of the Yaris’ NBC architecture (we suspect the latter), but this does provide a handy segue to…

Toyota Yaris HSD
With the 3rd-generation of the Toyota Yaris expected to debut during calendar year 2011 as a 2012 model and images already having leaked online, plus a story from the Mid-Japan Economist as reported by Reuters on 7 September of this year that Toyota plans to begin producing a hybrid version of the Yaris subcompact at its factory in Valenciennes, France, and it doesn’t take a rocket scientist to figure that this is the third Toyota hybrid in question. Don’t expect to see it in the U.S., however, as here the Yaris is too much of an entry-level vehicle for the cost-conscious to withstand a hybrid’s MSRP premium, and, notably, Honda also decided against selling its directly-competing Fit Hybrid in North America .

Do expect, however, to see both the “baby Prius” and Yaris HSD to be powered by something smaller and more fuel-efficient than the current Prius drivetrain. Prominent German automotive journalist Georg Kacher once erroneously predicted that the Euro-only Toyota Auris HSD hybrid (a Corolla variant) would use the 1NZ-FXE 1.5-liter 4-cylinder powertrain from the 2nd-generation Toyota Prius. He may have been right, however, insofar as these new smaller models. After all, its non-hybrid, Otto cycle variant, the 1NZ-FE propels the current 2nd-generation Yaris in North America.

Toyota Avensis HSD
Given that the current, 3rd-generation Toyota Avensis is built exclusively at the Burnaston plant in Derbyshire, England alongside its smaller Corolla-derived Auris sibling; that the latter’s HSD hybrid variant’s powertrain comes from the nearby Deeside engine factory; that said new variant debuted as part of the current Auris’ mid-life facelift (the 3rd-gen Avensis has yet to see its own mid-life facelift); and that Toyota Europe rejected the Lexus HS 250h mostly for its proximity to the top-of-the-line Toyota Avensis T Spirit, and it’s just a matter of putting two and two together and figuring that history may well repeat and see a Toyota Avensis HSD variant within the now-2012 time frame.

Not so obvious, however, is the powertrain question. The most expedient solution would be to, again, use the 2ZR-FXE 1.8-liter 4-cylinder from the 3rd-generation Toyota Prius, Toyota Auris HSD and Lexus CT 200h. Given that the gasoline-only 1.8-liter Avensis is already about 50-100 lbs heavier than the Prius and CT 200h without the latter two’s hybrid battery pack, and it may be asking too much to use 1.8-liter hybrid power for the Avensis. On the other hand, the Toyota Camry Hybrid and Lexus HS 250h’s 2AZ-FXE powertrain is not only somewhat outdated but probably too large for displacement-conscious Europe. A handy and logical solution, it would seem, may be to create a 3ZR-FXE 2-liter 4-cylinder hybrid powertrain from the 3ZR-FE 2-liter 4-cylinder gasoline engine that already powers the Avensis in some markets, and this might even work for the upcoming Toyota “Prius MPV”.

Toyota Sienna Hybrid
Of the seven vehicles here, this may, on the surface, appear to be the iffiest long shot. Yet, it wouldn’t be particularly difficult or far-fetched to imagine the Toyota Highlander Hybrid and Lexus RX 450h’s 2GR-FXE 3.5-liter V6-based hybrid powertrain making its way to the Sienna minivan, the largest and roomiest of the FWD-platform V6 Toyotas. This would certainly give new meaning to the whole Swagger Wagon concept!

Lexus IS h
With the Lexus IS line the marque’s current strongest seller in Europe (albeit soon to be surpassed by the CT 200h) and a move towards a hybrid-only strategy for the Old Continent by 2013 (as confirmed by Vice President of Lexus Europe Andy Pfeiffenberger), at least one hybrid version of the 3rd-generation Lexus IS, (expected to debut during 2012 as a 2013 model) is certainly to be expected. This would seemingly be an IS 350h powered by the IS 250’s 4GR-FSE 2.5-liter V6 plus a hybrid battery pack, roughly equalling the output of a typical 3.5-liter V6. Markets outside Europe could, theoretically, also see more powerful IS 400h (3GR-FSE 3-liter V6 plus hybrid motor) and even IS 450h (2GR-FSE 3.5-liter V6 plus hybrid motor) variants.

Lexus ES h
The Lexus ES, like its Toyota Camry parent, is due for the launch of a new generation within the now-2012 time frame, and it would only make sense for the carmaker to use the occasion to create an ES h model. The only question is whether it would skew towards economy and borrow the Toyota Camry Hybrid and Lexus HS 250h’s 2AZ-FXE powertrain (or, more sensibly, a 2AR-FXE successor based on the newer 2.5-liter 2AR-FE 4-cylinder engine), creating, say, an ES 300h; or towards performance by using the Lexus RX 450h’s 2GR-FXE 3.5-liter V6-based hybrid powertrain and making for an ES 450h. We’d suggest the latter, especially with the Lexus ES’s traditional focus on smoothness and quietness and with HS and CT series already holding down the fuel economy fort.

Other possibilities
While we strongly feel that these are the seven likeliest all-new hybrids, there are, of course, other more remote possibilities. There has been some talk that the so-called “Prius MPV” may come in shorter 2-row and longer 3-row variants, echoing other carmakers’ offerings in this segment (Ford of Europe, Renault, Nissan and Citroën come to mind) and Toyota’s own current RAV4/Vanguard in the Japanese Domestic Market. If that turns out to be the case, they may count as two separate vehicles. With all the talk of the full-electric Toyota/Tesla RAV4 EV, a separate hybrid RAV4 is unlikely, but you never know. It could also be that larger Camry-based offshoots not mentioned above, such as Toyota Avalon and Venza may, instead be the beneficiaries of hybridization. Conversely, going smaller, a Toyota Corolla or Matrix Hybrid would dovetail neatly from its Auris HSD fraternal twin, but if it wasn’t released concurrently with its just-announced mid-term facelift, don’t count on it. And the release of its all-new successor probably falls just outside the end-of-2012 window for the seven all-new hybrid Toyotas. Finally, we can’t discount the possibility that those seven new models include obscure, low-volume models sold exclusively in Japan, such as the Lexus HS-derived Toyota Sai.