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Hyundai Prius-fighting hybrid spied wearing new camo

Hyundai's engineers certainly don't want the public to see its upcoming dedicated hybrid model in several of these new spy shots, but the company can't deny that the machine is on the way. These test cars were first spotted last summer as Prius-like five-door hatchbacks. However in these photos and the second set, it would seem that the model has morphed into a more sedan-like shape similar to the Chevy Volt. Unlike the last time we saw this car during arctic testing, the vehicle no longer is covered in plastic concealment. That obfuscation has been replaced with a very effective camo pattern on everything but the roof, and in several photos, workers are actively standing in the way of the spy shooters' lenses. Beyond the whole model's general shape, there are a few details to pick out, though. You can easily spot the outline of the brand's hexagonal grille up front. There appears to be a rather complicated air dam design there, too. In profile, the shape of the rear hatch creates an integrated spoiler at the back. While the camouflage makes it very hard to tell, we don't see a plug-in port on this example. According to our spies, this test car was being driven with a slew of other electrified models, including a BMW i3, Nissan Leaf, Volkswagen e-Golf, and Kia Soul EV. Given that group, perhaps the engineers were specifically benchmarking the electric performance for this outing. Earlier reports suggest that Hyundai's latest hybrid could debut in the second half of 2016. Power reportedly comes from a 1.6-liter four-cylinder with hybrid assistance and a lithium-ion battery. Plug-in and five-door hatchback versions are also rumored.

Consumer Reports calls on Toyota to recall older Camry Hybrid models

Consumer Reports is calling on Toyota to issue an official recall of 178,000 Camry Hybrid sedans from model years 2007 to 2011, claiming that a pair of issues affecting the brakes are so dire they demand a more official action than what the company has undertaken so far.
The first issue, as CR tells it, relates to a clog in the brake-fluid reservoir filter, which if left untreated could lead to a number of dashboard warning lights. The "front brake assist could be temporarily lost," too, according to Toyota's own notice to dealers and owners of affected models. The company has issued a "service campaign" that will fit a new brake-fluid reservoir free of charge to any affected model brought to a dealer by June 30, 2017.
The other issue plaguing the fuel-sipping Camrys is being treated via a warranty extension, and focuses on the ABS brake actuator, a particularly expensive (both in terms of parts, at $1,000, and labor, around $3,000) item that is necessary for the anti-lock braking to function. There's also a related issue with the brake pedal's "stroke sensor," which like the actuator can lead to a very difficult-to-depress brake pedal. The warranty extension increases the coverage of the actuator to 10 years or 150,000 miles (whichever comes first).

How Toyota's 100-year textile history influenced FCV hydrogen fuel cell car

Turns out, Toyota had a surprising ace in the hole when it came to building the new fuel tanks for the FCV hydrogen fuel cell car, which is coming next year. Well before Toyota became the Toyota Motor Company, it was the Toyota Industries Corporation and it made textile looms. This is important because the main structure of the hydrogen tank is wound carbon fiber. When Toyota set out to increase the strength of the tanks to hold hydrogen stored at 10,000 psi (up from 5,000 in the previous tanks), it was able to draw on its 100-year-old history as it designed its car of the future. "A lot of that textile experience came back when we did the tank wrapping." – Justin Ward "We have a lot of experience with textiles," Justin Ward told AutoblogGreen at the 21st World Congress on Intelligent Transport Systems (ITS) in Detroit this week, "and a lot of that textile experience came back when we did the tank wrapping." On top of being able to hold the higher-pressure hydrogen, Toyota's first attempt to build its own hydrogen tank was six times faster than the industry standard, so it saved time and money as well as working better. The company will also be able to inspect its own tanks. Ward is the general manager of powertrain system control at the Toyota Technical Center and hydrogen vehicles are something he knows a lot about. The reason for the stronger, 10,000-psi tanks is because the 5,000-psi tanks only offered around 180-200 miles of range, even with four tanks in the early $129,000 FCHV Highlander hydrogen prototypes. The FCV only has two, but they will able to deliver the 300-mile range that customers told Toyota they wanted. Dropping the number of tanks not only obviously reduced the cost for the tanks themselves but also the number of valves and hoses and other components you need. Despite the benefits of higher compression, going much higher doesn't make sense. 10,000 psi is the "natural progression," Ward said, because "you start to bump up against compression inefficiencies." Think of an air compressor. When hydrogen is produced at a wastewater treatment plant or a reforming site, Ward said, is it at around ambient pressure (14 psi). That has to be raised, using compressors, all the way to 10,000 psi. "That takes energy," Ward said, "and every doubling of pressure adds another doubling of energy needed, so it starts to add up pretty fast if you go too high." Component specifications are also fine at 10,00 psi, but more difficult at higher levels.