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Akio Toyoda pledges return to WRC in 2017 with a Yaris

There have been rumors of Toyota returning to the World Rally Championship since the end of 2013, and a Yaris prepped by Toyota Motorsport in Germany has been caught on The Continent several times last year in testing. Akio Toyoda visited Rally Finland while we were there with Hyundai to watch a race up close, and he said that the passion people still had for Toyota's past exploits encouraged him. He finally answered the question about when they planned to enter the series, announcing in Tokyo that they'd line up for the season in 2017. The Japanese company, a legend in rallying, got into the sport in 1979 and left in 1999 after winning seven titles in ten years through the nineties with Carlos Sainz and Juha Kankkunen. The 2017 return is likely due to the regulation changes that year to allow more power than the roughly 300-horsepower in today's challengers and the switch to a fuel-flow formula to let manufacturers use different kinds of engines. Toyota has been sitting in on the WRC rules meetings, and the final slate of changes will be announced at the end of this year. The Yaris that's been testing is powered by a 1.6-liter, four-cylinder that meets current regulations, but we can expect it to change somewhat before it's race-ready. TMG will test the car for the next two years, then it will go up against fellow manufacturers Volkswagen, Hyundai, and Citroen, as well as Fords run by M-Sport. There's video of the Yaris running solo through the Belgian countryside above, and a gallery of the coming car below.

Toyota announces GT86 CS-R3 rally car

Toyota Motorsport GmbH has developed cars for all manner of racing, up to and including Formula One and Le Mans. But it got its start back in 1979 in rally competition, winning four drivers' and three manufacturers' titles in the World Rally Championship. And now it's announced a new rally car.
Based on the Toyota GT86 (better known to us as the Scion FR-S), the CS-R3 rally car isn't built to contest the top tier of the WRC, but is being developed to conform to the lower R3 class. That means a six-speed sequential gearbox, limited slip differential and upgraded engine, brakes, aero... the works. It'll retain the road-going model's rear-drive setup, joining the front-drive Yaris R1A in TMG's portfolio of customer rally cars.
Further details are set to be revealed "in the coming months", but the GT86 CS-R3 will benefit from the experience TMG accrued in developing the GT86 CS-V3 (pictured above) for the Nürburgring-based VLN endurance racing series.

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.