Toyota Operations Building a car

Build a car

Engine

Toyota Corporate Build a Car

The Engine Plant is where the four cylinder, 2.4 litre engine for the Camry is built. It uses Toyota's latest VVTi technology (Variable Valve Timing Intelligent technology) which enables improved fuel economy, lower emissions and improved performance. This is the first Australian-built engine with an aluminium block using high-pressure die casting.

Many of our engine components are manufactured in-house, including cylinder blocks, pistons, cylinder head covers, exhaust manifolds, intake manifolds and bearing caps. Others, such as cylinder block castings, are sourced from external suppliers.

Once completed, the engines head straight for the final assembly line.

Toyota Corporate Press Plant

Press

Toyota Australia's first Press Plant established in 1980 was the first Toyota Press Plant commissioned outside Japan.

The Press Plant produces steel panels and parts for Camry for Australian and export markets.

The largest press has a stamping force of about 2500 tonnes and the biggest panel produced is an entire body side of a Camry. Having a single panel for the side of the car, from windscreen pillar to tail-light, brings greater strength and quality while reducing weight and manufacturing complexity.

The body panels and parts are taken to the neighbouring weld shop.

Weld

Toyota Corporate Welding

The welding process isn't simply attaching the top, two sides, base, four doors, bonnet and boot lid.

The welding to make each car shell involves 250 processes and 526 parts. Robots do 105 of the welding jobs with the remainder being done by the 145 people on the day shift or the 145 people on the night shift. Maintenance of the welding equipment is carried out by 38 people.

The shell or body of the car then moves to the neighbouring paint shop.

Toyota Corporate Paint Shop

Paint

Employees wearing lint-free overalls are air-scrubbed before entering the dust-free world of the paint shop.

The car shells or bodies are immersed in water with cleaning fluids, in a phosphate dip to prepare the metal to accept the paint, and in the rust-proofing fluid. A spray bell then applies the primer and two coats of water-based paint with a fine mist.

The painted car shells are moved to the neighbouring assembly shop.

Assembly

Toyota Corporate Paint Shell

The painted car shells wind their way through seven assembly lines of about 250 metres each, travelling at a similar pace to a car in a car wash.

The car goes from a shell to a fully-tested finished product driven out of the assembly shop.