The carmaker says they chose the Hilux because it’s a global icon with a strong reputation when it comes to reliability and durability. These qualities had to be maintained even as it adopts an FCEV zero emissions powertrain.

The new powertrain in question uses core elements from the Toyota Mirai hydrogen fuel cell electric sedan—technology that has proved its quality in almost 10 years of commercial production. When driven, the fuel cell produces no tailpipe emissions other than pure water.

Hydrogen is stored in three high-pressure fuel tanks, giving the prototype Hilux an expected driving range of more than 600 kilometers—significantly further than might be achieved with a battery electric system. The hybrid battery, which stores electricity produced on-board by the fuel cell, is positioned in the rear load deck, avoiding loss of cabin space.

The project began in early 2022 with a feasibility study undertaken by Toyota Motor UK and Toyota Motor Europe. Funding was subsequently gained from the UK Government through the Advanced Propulsion Center, a non-profit organization supporting the development of cleaner technologies and new mobility concepts. This enabled the start of an intense design and development program from July 1, 2022 with consortium partners Ricardo, ETL, D2H Advanced Technologies, Thatcham Research, and additional support from Toyota Motor Corporation (TMC).

Prototype construction began on June 5 this year, working to Toyota Production System principles in a dedicated area within the TMUK facility. The first vehicle was completed just three weeks later, the first of 10 that will be built by the end of this year. These will undergo rigorous testing to ensure safety, dynamic performance, functionality, and durability meet the high standards required of a production model.