BMW 540i vs Toyota HiAce

What's the difference?

Not all superheroes wear capes, and we're proud to report the 530e does its bit for green motoring without feeling the need to shout about it. And with no price or specification penalty, it's easier being green than ever before, and the pricing of this BMW really puts the cat amongst the canaries.

The HiAce maintains its staggering 50 per cent share of the mid-size commercial van market for numerous compelling reasons including its versatility, as evidenced by the diverse range of Aussie businesses that rely on it. Toyota’s latest suite of safety and other upgrades makes it even better.

Crucially, there's nothing weird about the way the 530e looks. While some green cars look like they've been designed by one of the kids from 3rd Rock from the Sun, the 530e looks much the same as the rest of the range, save a few tiny but telltale giveaways - like the e-drive badging outside, and what looks like a bonus fuel flap tucked in behind a front wheel that houses the whole plug-in bit.

And we really, really like it. It's elegant and statesman-like from every angle, and looked especially important in the deep-blue colour of our test vehicle. It's not over-designed, with body creases used sparingly, and the occasional glint of polished silver that rings the windows and the grille adds a final sense of shininess to an understated design. 

Inside, there's more going on than you might normally find in a BMW. The hugely complicated digital display screen now includes everything from battery charge, power usage to the usual assortment of speedometers and petrol readouts. 

It doesn't feel overdone or crazily festooned, but there's more at play here than in your usual BMW.

The dash is busy, too, with a wide screen emerging from a centre stack that also houses a CD player and a digital aircon setup, which in turn sits above a complex centre console from which you can alter driving settings, control the multimedia or cycle through electric modes. It doesn't feel overdone or crazily festooned, but there's more at play here than in your usual BMW.

Elsewhere inside, the seats are beautifully designed, with a quilted leather highlight through the middle, while the gloss-black strip that lines the dash hides a dual strip of ambient interior lights that also runs across all four doors.

Apart from the recent safety upgrades, our LWB test vehicle resolutely adheres to a design that’s been perfected through decades of hard yakka.

Its simple and robust unitary chassis features MacPherson strut front suspension, a leaf-spring live rear axle, rack and pinion steering and (on all automatic variants) four-wheel disc brakes.

The HiAce’s traditional rear-wheel drive layout has an inherent traction advantage over front-wheel drive rivals, particularly when towing and hauling heavy loads on low-grip surfaces.

It also ensures the front wheels can be turned sharply enough for its 3210mm wheelbase to deliver an impressively tight 11.0-metre turning circle. And its 1990mm height also allows access to underground loading docks and multi-storey car parks.

There’s no load-floor liner or cabin bulkhead included as standard equipment, but both are available as Toyota genuine accessories. The use of unpainted plastic bumpers is designed to best withstand the wear and tear often evident in these areas on hard-working vans.

The cabin is spacious and airy, with a neat and functional dash design featuring large and clear instrumentation and (thankfully) physical dials and buttons rather than distracting touchscreens for the main controls that are easy to reach and operate. It’s a commercial van that’s easy to live with.

As the world's motoring tastes shrink faster than a lap-banded Clive Palmer, it's easy to forget the joys of the full-size sedan, but the space for passengers and luggage in the 5 Series will have you questioning your downsizing ways.

Upfront, there's plenty of room between front-seat riders, who will also share two smallish cup holders, along with room in each front door for bottles. There's also a dedicated wireless charge pad (which, because of its tight design, is crazy difficult to actually remove your phone from), but you'll also get two USB points and a power outlet that's hidden in the sizeable centre storage bin as standard fit.

Backseat riders get heaps of space, both in width and in leg room behind the front seats. And there's twin air-con temp controls and twin power outlets, too. But middle-seat passengers will be forced to sit with their legs on either side of the raised tunnel, which will definitely impact on comfort.

The boot's still sizeable, despite shrinking slightly to house the battery/fuel tank setup

Best to ditch the fifth passenger, then, and deploy the pull-down seat divider, which also houses two cup holders. Finally, there are three ISOFIX attachment points, one for each seat in the back.

The boot's still sizeable, despite shrinking slightly to house the battery/fuel tank setup (the tank has been moved further back to accomodate the batteries), and can be adjusted to be a flat load area if you'd like, offering up to 410 litres with the rear seats in place.

With its hefty 2260kg kerb weight and 3300kg GVM, our test vehicle has a 1040kg payload rating. So, it’s a genuine one-tonner and up to 120kg of that can be carried on Toyota’s triple roof-rack set.

The HiAce is also rated to tow up to 1500kg of braked trailer and with its 4800kg GCM rating (or how much weight it can legally carry and tow at the same time) it can carry its maximum payload while towing its maximum trailer weight. So, that’s more than 2.5 tonnes of combined cargo-carrying capacity, which would comfortably meet or exceed most job requirements.

Its cavernous cargo bay, which offers 6.2 cubic metres of load volume, is accessed from either side through sliding doors with 1010mm-wide openings, or through rear barn-doors with 180-degrees opening to allow easy forklift access.

The cargo bay is 2530mm long, 1760mm wide and 1340mm high, with 1268mm between the rear wheel housings allowing up to two standard Aussie pallets or three Euro pallets to be carried, secured by a choice of six load-anchorage points.

An unusual feature is the roof’s full-length internal lining, which we suspect contributes to at least some suppression of tyre noise emanating from the rear-wheel housings. The walls and doors are neatly lined to mid-height and there’s ample internal lighting.

Generous cabin storage includes a bottle-holder and bin in each front door, small bottle/cupholders in the centre and either side of the dash, plus a single glove box. The console between the seats offers another two bottle-holders plus generous internal storage, which is topped by a large hinged lid that can also serve as a storage tray or work desk.

The base model LWB HiAce two-seater van comes standard with Toyota’s signature 2.8-litre four-cylinder turbo-diesel (shared by all HiAce models) and manual gearbox for a list price of $51,880, but our test vehicle is equipped with a six-speed automatic and rear barn-doors which raises the price to $54,630.

Other standard equipment includes Vanilla White paint, 16-inch steel wheels with replaceable plastic covers, 215/70R16 tyres and a full-size spare, halogen headlights and DRLs, leather-accented steering wheel with multiple remote functions, power-adjustable lumbar support on the driver’s seat, a USB port and 12-volt cabin sockets, an 8.0-inch touchscreen to control the two-speaker multimedia system with Apple CarPlay/Android Auto connectivity and more.

Recent upgrades to optimise driver comfort include a new 7.0-inch digital driver’s instrument cluster (previously analogue) with nine selectable displays, plus a new refrigerant to improve air conditioning performance (even though the previous system was always ice cold), an electronic parking brake on automatic models to replace the old-school mechanical lever and electric power steering to replace Toyota’s traditional hydraulic power assistance for reduced steering effort and more advanced lane-keeping smarts.

The latest safety upgrades include ‘lane trace assist’ which is designed to help the HiAce remain in the centre of its lane when the adaptive cruise is activated (see Driving).

There’s also a new ‘emergency driver support system’ which works with lane trace assist to detect if the driver has become unresponsive when adaptive cruise is activated. If the driver doesn't respond to audio and visual alerts, the system is designed to activate the hazard lights and bring the vehicle to a safe and steady stop.

Other upgrades include ‘safe exit assist’ which links with the van’s blind-spot monitor to improve safety when exiting the vehicle on the roadside, by issuing alerts when passing vehicles or cyclists are detected.

Cruise control functionality has also been expanded, with automatic grades like ours getting ‘full-speed function’ which can automatically stop the vehicle and then resume moving without the driver needing to intervene. This is especially useful in heavy stop-start city traffic.

Passive safety has also been improved with an additional centre airbag which protects driver and passenger from colliding in an accident.

Drift around in pure EV mode and you'll be relying on the 530e's 83kW and 250Nm electric motor, which will provide what BMW refers to as "between 28 and 32 real-world kilometres".

Run out of range, or simply use too much throttle, and the 2.0-litre petrol engine comes into play, adding 135kW and 320Nm to the mix. All up, that's 185kW and 420Nm - respectable numbers by any measure, and enough to match the petrol-powered 530i's zero to 100km/h sprint of 6.2 seconds.

That power is fed through an eight-speed automatic transmission before being sent exclusively to the rear wheels, where it belongs.

Toyota’s well-proven (1GD-FTV) 2.8-litre, four-cylinder, turbo-diesel produces 130kW of power at 3400rpm and, in auto models like ours, 450Nm of torque between 1600-2400rpm. Its Euro 5 emissions compliance doesn’t require AdBlue, which minimises maintenance and running costs.

The refined six-speed torque converter automatic offers the choice of sequential manual-shifting. Fuel efficiency is optimised with full torque converter lock-up on fourth, fifth and sixth gears, along with overdrive on fifth and sixth to minimise engine rpm when highway driving. The traction advantage of rear-wheel drive is enhanced by an electronically controlled automatic limited-slip diff.

Like a Facebook relationship status, it's complicated. The 530e will sip a claimed combined 2.3 litres per hundred kilometres on the claimed/combined cycle, which is amazing for a car this size. Better still, it seems genuinely achievable - at the vehicle's launch, our own Richard Berry recorded a stunning 2.0 litres per hundred kilometres on a short test route.

But that's with a full load of battery charge on board. For our week with the 530e we were unable to actually plug it in (living in Sydney, I can't afford a garage), so once the initial battery charge had been used we were back to mostly petrol power. Unlike some other plug-in hybrids we've driven, we found it very difficult to recharge the battery to any meaningful level using regenerative braking, so once we were flat we stayed flat. If we had plugged it in, it would have been a two-hour recharge using a specialised wall unit, or about four hours using a normal plug.

As a result, though, our fuel use was closer to 7.0 litres per hundred kilometres after some considerable real-world testing.

Toyota claims combined cycle (urban/extra-urban) average consumption of 7.8L/100km. Our 328km of testing was conducted with the engine’s auto start/stop function switched off and comprised the usual mix of city, suburban and highway driving, of which about one third was hauling a near-maximum payload.

Our own figure, calculated from fuel bowser and tripmeter readings, was 10.7L/100km. That’s still within the usual 2.0-3.0L/100km discrepancy between official and real-world figures and not bad for a vehicle weighing more than 2.2 tonnes driven mostly in metro settings and hauling more than one tonne during our test. So, based on our real-world consumption, you could expect a driving range of around 650km from its 70-litre tank.

There's so much to like about the way the 530e sets about saving the world, and that's mostly because it doesn't shout about it, either to the driver or the outside world.

It's very much an underpants inside its pants superhero, which makes us like it even more. Set off in EV mode, and the 530e will drift silently away from the curb, burning battery power over fuel for as many as 30(ish) kilometres. But equally important, the shift from green to gas is largely imperceptible, with the petrol engine joining in willingly when you ask it to - usual via a prod of your right foot.

It is so effortlessly smooth that you need to really pay attention to notice the eight-speed 'box changing gears at city speeds, and it's commendably quiet, whichever drive mode you're in.

Downsides? Well, it doesn't feel quite as sharp as it's conventional-engined siblings. The batteries add around 230kg in weight, which never helps, and it all feels a little softer and a little less dynamic, even with Sport mode engaged. BMW assures us the adaptive suspension setup and tune is identical, but the 530e feels noticeably softer when you tackle a twisting back road. And that encourages you to use your right foot a little more, which in turn negates the whole electric thing in the first place.

One of the great joys of BMWs has always been their ability to transform from cosseting comfort to rear-drive rocket when you want them to, and you can't help but notice the 530e isn't quite up to that challenge. But if your intentions are mostly city- and freeway-based, then this plug-in BMW is almost indiscernible from its petrol-powered sibling.

The driving position is comfortable thanks to a well-sorted combination of supportive seating with power-adjustable lumbar support, a leather-rimmed steering wheel that’s adjustable for height and reach and a large left footrest for extra support.

The standard kerbside sliding door includes a large window, which partly reduces the huge blind spot over the driver’s left shoulder created by the cargo bay’s solid walls.

Fortunately, the HiAce also comes standard with blind-spot monitoring to ensure safe lane-changing on multi-lane roads, while its rear cross-traffic alert and rear-view camera are equally valuable when reversing out of driveways into busy traffic.

The new electric power steering has more noticeable changes in turning weight compared to the more linear hydraulic system it replaces. Its variable-ratio assistance feels even lighter at parking speeds for easier manoeuvrability and becomes increasingly firm and direct as road speeds increase.

Ride quality is reasonably supple when unladen or lightly loaded and the 2.8-litre turbo-diesel, with its sizeable 450Nm of torque, has strong low-rpm response and displays good flexibility in city and suburban driving.

Internal noise levels below 80km/h are acceptable, but like all vans can become intolerable at highway speeds due largely to tyre roar emanating from the rear-wheel housings. So, if you do lots of highway travel, we’d recommend fitting Toyota’s genuine accessory solid bulkhead to insulate the cabin from this noise.

The six-speed auto’s shift calibrations feel like they’re getting the best out of this engine, particularly fuel-efficient highway travel which requires less than 2000rpm to maintain 110km/h. The sequential manual-shifting function can be handy in certain situations, though, like hauling/towing heavy loads in hilly terrain.

To test its GVM rating we forklifted 830kg into the cargo bay, which combined with our crew of two equalled a total payload of 1010kg that was only about 30kg less than its 1040kg limit.

The stout rear leaf-springs only compressed about 30mm, which left more than 60mm of static bump-stop clearance that was more than enough to ensure there was no bottoming-out on our test route.

Its ample torque made light work of hauling this payload in city, suburban and highway driving as well as our 13 per cent gradient, 2.0km-long set climb at 60km/h, which it easily cleared in third gear.

Engine braking on the way down, in a manually-selected second gear, wasn’t as robust but within expectations given the one-tonne-plus payload it was trying to restrain.

We also tested what we safely could of the HiAce’s latest safety upgrades in road use, which all worked as intended. The ‘lane trace assist’ function when using adaptive cruise control was outstanding, as it resolutely kept the vehicle centred in its lane even around curved stretches of multi-lane highway, without the driver needing to intervene.

The HiAce comes with a fresh maximum five-star ANCAP rating awarded in 2025 and a top-tier Platinum rating in ANCAP’s commercial van collision avoidance assessment. Both rankings are courtesy of the latest safety upgrades, which enhance the HiAce’s existing suite of features that includes AEB with pedestrian and daytime cyclist detection, speed sign recognition, blind-spot monitoring, rear cross-traffic alert, front and rear parking sensors, reversing camera and lots more.

The airbag count runs to eight - dual front, side chest, side head, centre and driver's knee.

Like the rest of the 5 Series range, the 530e falls under BMW's three-year, unlimited-kilometre warranty. There are no set service intervals, either, with BMW using what it calls 'condition-based' servicing. In other words, the car will tell you when it requires a trip to the service centre.

The batteries are covered by a separate warranty covering six years or 100,000km.

The HiAce is covered by Toyota's five-year/unlimited km warranty which is in line with competitors like the Ford Transit Custom and Hyundai Staria Load but lags behind the LDV Deliver 7's seven-year term.

Scheduled servicing is a relatively short six months/10,000km interval, whichever occurs first. Capped price for the first 10 scheduled services up to five years/100,000km totals $3650, which is $365 per service or $730 annually.

Toyota currently has 275 dealers across its vast Australian network located in metro, rural and regional areas. Toyota dealerships are also service centres.