UK PRESS RELEASES

The New Toyota Avensis 2.2 D-4D And 2.2 D-4D Clean Power
1 March 2005

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Effortless performance with superior quality

KEY POINTS

Two new 2.2-litre D-4D engines for Toyota Avensis presented at the Geneva Motor Show
2.2 D-4D
Maximum power 148bhp and 310Nm from 2,000 to 3,200rpm
Lightweight all-aluminium construction
New, compact six-speed manual transmission
Targeted top speed of 130mph and 0-62mph in 9.3 seconds
Targeted combined fuel consumption of 47.1mpg and CO2 emissions of 157g/km
Available in the UK from June 2000
2.2 D-4D Clean Power
On sale in the UK in early 2006
Class-leading performance: 175bhp and 400Nm from 2,000 to 2,600rpm
Combined fuel consumption on average 20 per cent lower than rival engines with similar
output (target figure)
Lighter than most engines in segment, 11 per cent lighter than current 2.0-litre D-4D unit
World’s lowest compression ratio for a production diesel engine, 15.8:1, aiding quieter
operation and better performance from start-up
Electrically-activated turbocharger with turbine wheel inertia reduced by 30 per cent for
quicker engine response
Toyota D-CAT system makes engine the cleanest on the market for combined nitrogen
oxides (NOx) and particulate matter (PM) emissions
Class-leading cost of ownership profile
Both engines produced in Poland by Toyota Motor Industries Poland (TMIP)
Complete Avensis engine range remains Euro IV compliant
Avensis driving dynamics improved with new suspension settings and NVH package

INTRODUCTION

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

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

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

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

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

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

TOYOTA 2.2-LITRE D-4D ENGINE

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

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

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

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

TOYOTA 2.2 D-4D CLEAN POWER

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

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

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

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

NEW INJECTION AND INDUCTION TECHNOLOGIES

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

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

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

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

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

WORLD-BEATING EMISSIONS CONTROL SYSTEM

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

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

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

NEW SIX-SPEED MANUAL TRANSMISSION

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

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

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

CLASS-LEADING COST OF OWNERSHIP

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

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

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

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

IMPROVEMENTS IN DRIVING DYNAMICS

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

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

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

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

ENGINE
2.2 D-4D 2.2 D-4D CLEAN POWER

Type
In-line 4-cylinder with Variable Nozzle Turbocharger and intercooler

Cylinder head material

Aluminium

Engine block material

Aluminium

Fuel type
48 Cetane diesel (or more)

Injection type
Direct, common rail, multiple fuel injection

Injection pressure (bar)

1600 1800

Emission control system

Oxidation catalyst Toyota D-CAT + oxidation catalyst

Valve mechanism
DOHC 16-valve

Displacement (cc)
2,231

Bore x stroke (mm)

86.0 x 96.0

Compression ratio (:1)

16.8 15.8
 Max. power (bhp/rpm)
148@3,600 175@3,600

Max. torque (Nm/rpm)

310@2,000-3,200 400@2000-2600

TRANSMISSION

Drive type
Front-wheel drive

Gearbox type
Six-speed manual

PERFORMANCE

Max. speed (mph)

130 137

0-62mph (sec)
9.3 8.6

FUEL CONSUMPTION

Combined* (mpg) Saloon/hatch

47.1 46.3

Tourer
47.1 45.6

CO2 EMISSIONS

Combined* (g/km) Saloon/hatch

157 161

Tourer
159 163

* According to Directive 1999/100/EC

ENDS