The new Toyota RAV4 hybrid

THE SAME PIONEERING spirit is witnessed in the all-new fifth generation RAV4, a model which brings a new era of improved performance, capability and safety. These advances that are underpinned by the first use of Toyota’s new GA-K platform in an SUV.

With its low centre of gravity and significantly increased body rigidity, the new RAV4’s platform directly contributes to superior handling, ride comfort, a spacious interior, class-leading load space (580 litres VDA with seats in place) and the freedom to produce a strong, eye-catching design with lower roof and hood lines and higher ground clearance. As well as providing more space and comfort, the cabin displays exceptional quality and finish throughout.

The new RAV4 remains unique its class in offering customers a self-charging, hybrid powertrain – the choice of an overwhelming majority of customers for the model in Western Europe (85 per cent in 2018). The new 2.5-litre petrol hybrid Dynamic Force, offering 218 DIN hp in front-wheel drive form and 222 DIN hp with all-wheel drive, will strengthen customer appeal, delivering step-changes in power, responsiveness and efficiency, with best-in-class fuel economy and emissions levels.

At the same time, all-wheel drive systems have been comprehensively improved to achieve a “drive on any road” capability. The new RAV4 Hybrid’s electric AWD-i system has been re-engineered and enhanced to provide much stronger performance in challenging conditionsand secure handling on slippery surfaces.

The new RAV4 is also the first Toyota to benefit from additional Toyota Safety Sense features that extend the use of advanced technologies to help prevent accidents and provide greater driver assistance, including systems that introduce a degree of automated driving.

RAV4 HERITAGE AND MARKET SUCCESS

The Toyota RAV4 started out as a pioneering niche model but has gone from strength to strength to become one of the world’s best-selling vehicles. It can be credited with creating a whole new market segment, one in which today every major manufacturer is represented.

The model now sits at the heart of Toyota’s global business. Cumulative worldwide sales across four generations since 1994 have reached more than 8.5* million, while in 2017, RAV4 was the world’s best-selling SUV and fourth best-selling model overall, with 810,953 sales.

In Europe, high customer demand for SUVs has seen the market increase four-fold in the past four years (accounting for 22.7 per cent of the new car market) and annual sales are expected to reach more than five million by 2023. Sales volumes in the D-SUV segment remain stable, at around 1.5 million a year.

* End of June 2018

 

TOYOTA NEW GLOBAL ARCHITECTURE

GA-K PLATFORM

The foundation of the new RAV4’s dynamic qualities is its all-new TNGA K platform.

This gives the car the core strengths of a low centre of gravity, light weight and a strong, rigid and balanced chassis that delivers exceptional handling, stability and driver rewards.

FOR THE CUSTOMER the new platform makes the car more fun to drive, while at the same time enabling great design inside and out, enhanced safety performance that gives greater peace of mind and greater comfort for everyone on board.

The lowest possible centre of gravity is achieved by making every component lighter and locating it lower down in the vehicle – everything from the engine to the seats in the cabin. The platform also allows for a 57 per cent increase in the RAV4’s body rigidity, which contributes to a stable, flat ride with superior handling.

The GA-K platform underpins the “confident and natural” driving quality Toyota has sought for the new model: “confident” in not reacting adversely to disturbances and communicating a sense of stability, and “natural” in its intuitive, natural response to the driver’s inputs. Beyond the benefits of the chassis itself, further detailed measures make important contributions to its overall quality, with Toyota’s top engineers leading the development of the new RAV4’s dynamic performance, fine-tuning its handling and driveability

For example, the design and location of the fuel tank have been changed to achieve better handling and stability. The tank is now located laterally in front of the rear axle so that its load is spread evenly between the wheels, supporting flat, stable performance. Optimum weight balance is not only achieved front-to-rear (59/41) but also left-to-right.

Response from the Electric Power Steering has been improved by moving the assist motor from the column to the rack. The result is more linear increase in steering input torque and less strain on the steering shaft, which communicates a better, more direct feel to the driver as the steering loads up, and gives more faithful line tracing through corners. Summer-specification tyres are used in place of the all-weather type, further adding to the precise driving quality and achieving top-class braking distances.

The RAV4’s GA-K platform also distinguishes itself in its use of a double wishbone rear suspension system. Thanks to the low centre of gravity and high body rigidity, the suspension does not have to be rendered stiffer to meet dynamic targets. Nonetheless, precise adjustments have been made to the rear suspension to focus on better ride comfort, including a more upright setting for the shock absorbers and optimisation of the locating point for the trailing arms.

Handling is thus agile, faithful and neutral, giving the driver confidence with accurate responses to the driver’s use of the steering wheel and throttle pedal and optimised shift patterns.

 

CONCEPT AND DESIGN

The TNGA GA-K platform was of great benefitto Toyota’s designers in their mission to give the new RAV4 a strong SUV character and styling that sets it apart from other models in its segment.

THE FACT THAT TNGA introduces so many standardised parts “under the skin” simplifies the development process, giving the designers more time and scope to create an all-new look, inside and out. The exterior lines and detailing in the cabin are influenced by regular, polygonal shapes, communicating strength and coherence.

The powerful design combines with the unique new self-charging hybrid powertrain to give the new RAV4 the stand-out qualities required to attract customers in a highly competitive marketplace, in particular conquest sales to people new to the model and the Toyota brand.

Key elements in generating this impact include raising the ground clearance, using large diameter wheels and making the car suitable for multiple types of use.

The exterior look is powerful and individual, with a solid form that extends from the front the vehicle along the sides to the rear, giving the sense of a strong mass and authentic SUV capabilities. At the front the emphasis is on width and strength with extra volume added to the lower bumper section. There is a similar effect at the rear where the horizontal line created by the tail lights and back window angles sharply downwards at each edge, drawing the eye towards the rear wheels and expressing the “polygon” influence on the design.

The cabin is characterised by high sensory quality throughout and precision execution. Soft-touch surfaces abound, including the dashboard and door panels. Consistent patterns, textures, colours and ambient lighting are applied, with symmetrical shapes and use of the polygon motif seen in the Toyota FT-AC (Future Toyota – Adventure Concept, premiered at the 2017 Los Angeles Auto Show) concept model. Switchgear is new, too, with cleanly integrated buttons and pleasingly tactile controls, such as the button/dial to adjust the air conditioning

The low-set instrument panel – a further benefit of the TNGA platform – has powerful horizontal lines that flow into the door panels, emphasising the cabin’s generous width and giving the driver a clearerview of the road ahead. A larger, open centre console between the front seats is in keeping with a welcoming, functional SUV interior. Special attention was paid to providing plenty of useful and easily accessible storage for the driver and front passenger.

The TNGA platform also helps secure impressive cabin space, best-in-class load space and all-round comfort. With all seats in place, the cargo area has a VDA capacity of 580 litres, 79 litres more than the previous generation RAV4 Hybrid. Reducing the front and rear overhangs by a combined 35 mm (-5 mm front, -30 mm rear) means the new model is shorter overall by 5 mm (4,600 mm) and retains its agilemanoeuvrability, yet the wheelbase has been increased by 30 mm (2,690 mm), securing a more spacious cabin.

To add to the new model’s purposeful, wide stance, overall width has grown by 10 mm (1,855 mm) and the front and rear treads have been increased. At the same time, overall height has been brought down by 10 mm.

ON-BOARD COMFORT AND CONVENIENCE

Securing better all-round visibility was a key consideration in the RAV4’s design process. The TNGA platform allows the hood to sit 15 mm lower, adding two degrees to the driver’s forward field of vision, and the external mirrors have been moved to a lower position on the front doors. The front pillars have been made slimmer, the belt line has been lowered and the rearward view from the driver’s seat has been improved by enlarging the rear side windows and making a new digital rear-view mirror available (further details in the Equipment section).

The driver’s comfort and sense of control when at the wheel are important considerations, and the new TNGA chassis allows for a more engaging driving position, without detracting from the commanding view of the road that’s a defining quality of SUVs. The driver’s hip point has been lowered by 15 mm and the range of steering wheel adjustment has been increased by 50 per cent. This, together with a generousseat adjustment range and precise positioning of the pedals and arm rest, ensures more customers are able to find their ideal position when driving.

Comfort for rear seat passengers has been improved with 40 mm addedto the left/right couple distance, more spacious rear footwells and two air vents. By increasing the opening angle of the rear doors and reducing the distance from the hip point to the rocker panel, getting into and out of the vehicle and access to child seats has been made easier.

The load space behind the rear seats has been made larger and more user-friendly, notably thanks to a fully flat floor and a length extended by 60 mm to secure best-in-class capacity, 79 litres more than in the previous, fourth generation RAV4. Flexibility is designed-in so that the space can easily be adapted to gain more cargo room when required: with the rear seats folded down, the new RAV4 can accommodate a 29-inch mountain bike without any wheels having to be removed.

There is a height-adjustable, two-level deck board that can be reversed when dirty items need to be carried. The rear seats have a 60:40 split-folding function and there are storage nets on each side of the boot. Clever details include a hand grip on the tailgate that can serve as a hanger and a power-operated tailgate with hands-free function.

 

POWERTRAINS AND PERFORMANCE

The new 2.5-litre Hybrid Dynamic Force combines fuel and emissions efficiency

and quiet operation with more power and greater responsiveness.

THE FULL SYSTEM maximum output of 222 DIN hp/163 kW in the all-wheel drive model (218 DIN hp/160 kW with front-wheel drive) compares to 197 DIN hp/145 kW for the fourth generation model, signalling how Toyota’s latest self-charging hybrid technology is not lacking in strength; acceleration from rest to 100 km/h takes just 8.1 seconds.

The proposal of “power with no compromise” gives the new RAV4 a unique advantage in its class and, with the benefit of its improved performance, driveability and efficiency, this new hybrid is expected to account for an even greater proportion of sales. Toyota expects that this will rise from the current 85 per cent to 90 per cent for the new model in Western Europe. Nevertheless, a brand new 2.0-litre direct injection petrol engine has also been developed to meet requirements in other global markets. This engine will be available in selectedEuropean markets, with a choice of manual or automatic transmissions.

Toyota’s fourth generation self-charging hybrid system makes its debut in the new RAV4, delivering multiple benefits. Key components, including the power control unit (PCU) and the nickel metal-hydride battery are more compact and lighter in weight, and the transaxle and transmission have been engineered to reduce electrical and mechanical losses. The new battery pack is 11 per cent lighter than before and transmission losses have been reduced by 25 per cent compared to the previous system.

The system makes use of Toyota’s new 2.5-litre Hybrid Dynamic Force engine, a four-cylinder unit with direct and indirect injection that targets best-in-class fuel consumption and emissions for the new RAV4: combined cycle fuel economy is 4.4 l/100km* (AWD-i correlated NEDC), with CO₂emissions from as low as 100 g/km* (AWD-i correlated NEDC). Performance is also supported by a new transaxle structure with a pre-load differential. For the driver, the results are better acceleration from stationary, improved efficiency at higher speeds, overall smoother and more linear acceleration and better control when decelerating.

NEW 2.5-LITRE HYBRID DYNAMIC FORCE ENGINE

The 2.5-litre Hybrid Dynamic Force Engine is a completely new unit that makes significant advances on its predecessor, delivering a better balance between fuel economy and power and achieving world-class thermal efficiency. In the RAV4’s self-charging hybrid powertrain, its CO₂emissions are from just 100 g/km* (AWD-i with 17inch wheels), while maximum full system output is 218 DIN hp/160 kW for the FWD model and 222 DIN hp/163 kW with AWD-i.

The engine adopts the Atkinson cycle and features a longer stroke than its predecessor – 87.5 x 103.4 mm compared to 90.0 x 98.0. It also operates at a higher, 14.0:1 compression ratio (compared to 12.5:1 for the previous unit). It is equipped with D-4S direct and indirect fuel injection and intelligent variable valve-timing – electric VVT-iE for the intake and hydraulic VVT-i for the exhaust. The valve-timing range for both intake and exhaust has been increased.

A comprehensive range of engineering features destined to improve combustion and reduce friction losses has helped the new engine achieve high output, better fuel efficiency, low exhaust emissions and a high peak thermal efficiency of 41 per cent. The cylinder heads are designed to generate high tumble, with an enlarged valve included angle and laser-cladded valve seats. A variable cooling system with an electric water pump and electric thermostat is used to improve combustion by maintaining the required temperature. There is also a fully variable oil pump for efficient engine oil pressure management.

INTELLIGENT ALL-WHEEL DRIVE (AWD-i)

Toyota is introducing improvements to its intelligent all-wheel drive technology (AWD-i) in the new RAV4 to deliver enhanced performance, capabilities and control in all driving conditions, adding to the model’s “go anywhere” spirit and driving pleasure. Its impressive all-wheel drive performance on-road and off will further distinguish the new RAV4 among its competitors, with secure cornering performance and grip in all conditions.

RAV HYBRID WITH SIGNIFICANTLY ENHANCED ELECTRIC AWD-i SYSTEM

The new RAV4 Hybrid is equipped with a significantly enhanced and more capable electric AWD-i system that comes with no penalties: it returns better fuel economy in urban driving, quieter performance at high speeds and better traction in slippery conditions. It is also more compact and lighter in weight than mechanical AWD systems, so fuel consumption and vehicle packaging are not compromised.

The system efficiently generates drive torque using power from the hybrid vehicle system and an additional motor on the rear axle. This design reduces energy losses, saves weight and optimises AWD operationin different driving conditions.

Compared to the fourth generation model, the maximum torque to the rear wheels has increased by 30 per cent, from 953 to 1,300 Nm, matching or surpassing the torque achieved by mechanical systems and giving more sure-footed performance, for example when pulling away on loose, slippery surfaces. Also, the front/rear split can vary from 100:0 to up to 20:80, depending on driving conditions.

The electric AWD-i system automatically optimises the torque ratio according to driving conditions, providing improved handling, stability and off-road performance, particularly in faithful line tracing through bends in slippery conditions, giving the driver a strong feeling of all four wheels being in good contact with the road.

The mechanical all-wheel drive system on the new RAV4 2.0-litre direct injection petrol CVT model is equipped with Toyota’s first dynamictorque vectoring system with Rear Driveline Disconnect. Featuring twin couplings on the rear axle, this manages torque distribution between the left and right rear wheels to give stable performance and accurate response to the driver’s steering inputs when cornering, both in dry and slippery conditions.