Toyota ZZ engine

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The Toyota ZZ engine family is a straight-4 piston engine series. The ZZ series uses an aluminum engine block and aluminum DOHC 4-valve cylinder heads, a first for Toyota. The valve camshafts are chain driven. The two 1.8 L members of the family, the 1ZZ and 2ZZ, use different bore and stroke. The former was optimized for economy and torque, while the latter is a "square" design optimized for high-RPM power. The ZZ family replaced the extremely popular cast-iron 4A engines.

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[edit] 1ZZ-FE

The 1ZZ-FE is a 1.8 L (1794 cc) version built in Buffalo, West Virginia and Cambridge, Ontario. Bore is 79 mm and stroke is 91.5 mm. Output is 130 hp (97 kW) at 6000 RPM with 125 ft·lbf (169 N·m) of torque at 4200 RPM. The cylinders of 1ZZ engines are lined with cast iron. It uses SFI fuel injection, has VVT-i (on later versions) and features fracture-split forged powder metal connecting rods, a one-piece cast camshaft, and a cast aluminum intake manifold.

Applications:

[edit] References

[edit] 1ZZ-FED

The 1ZZ-FED is similar to the 1ZZ-FE but is built in Shimoyama, Japan. Output is 140 hp (104 kW) at 6400 RPM with 126 ft·lbf (171 N·m) of torque at 4200 RPM. It uses MFI fuel injection, VVT-i and light weight cast rods.

Applications:

[edit] 2ZZ-GE

2ZZ-GE Engine in the Corolla XRS
2ZZ-GE Engine in the Corolla XRS

The 2ZZ-GE is a 1.8 L (1796 cc) version built in Japan. Bore is 82 mm and stroke is 85 mm. Output is 180 hp (134 kW) at 7600 RPM with 130 ft·lbf (176 N·m) of torque at 6800 RPM. It uses MFI fuel injection, has VVTL-i, and features forged steel connecting rods. Compression ratio is 11.5:1. Unlike others in the ZZ family, the 2ZZ-GE requires "premium" gasoline - 91 octane or above in the USA. Power output for this engine varies depending on the application and tuning, with the Lotus Elise and Lotus Exige offering 190 hp but the Pontiac Vibe, Toyota Corolla and Toyota Matrix versions only developing 180 hp (+2005: 170 hp). The Australian variant (Corolla Sportivo and Celica GTS) is 141kw@7600 and 181N·m Torque due to noise regulations. (Toyota recalled them for a flash of the ECU to up their output to put them into the more lenient "sports car" noise category). The Corolla Compressor and Lotus Exige S add a supercharger to achieve 225 hp, while the Exige 240R's supercharger increases output to 240 hp.

The 2ZZ-GE utilizes a dual camshaft profile system (the "L" in VVTL-i, known by enthusiasts as "lift"), to produce the added power without an increase in displacement or forced induction compared to the lesser engines in the ZZ series. This is similar in concept to Honda's i-VTEC, but the two systems are very different in design and execution.

The 2ZZ-GE engine is also the only engine in the ZZ engine family to use a six-speed manual transmission, and also the only one to use a four-speed Tiptronic-style automatic (with upshift buttons on the back of the wheel and downshift buttons on the front of the wheel). These gearboxes were unique to this engine; since then, only a few Toyota engines have been paired with either a six-speed manual or a Tiptronic-style automatic (and only one engine, the 4GR-FSE, has received both]].

Disintegrated oil pump
Disintegrated oil pump

Toyota commissioned Yamaha to design the 2ZZ-GE, and it shares several similarities with street bike engines, the most notable being the relatively high RPM design. The high-output cam profile is not activated until above 6000 RPM (the exact point of engagement is different depending on the vehicle, year, and ECU involved). On all of the Toyota-built vehicles, redline begins at 8200 RPM while the tachometer is typically numbered to 9000, giving an incredibly small "unusable" range. The Toyota ECU electronically limits RPM to about 8200 (through fuel and/or spark cut). It is impossible to "over-rev" the engine with the throttle alone; a downshift from a higher gear is required. But if you manage to do it, the oil pump commonly disintegrates the lobe ring.

The motor will happily run at ~4000 RPM for extended periods of time, and during stress testing the motor will run at the 8200RPM redline for extended periods without issue. For the first few years of production, the engines were notorious for breaking off the "lift bolts" inside the engine. This didn't do any damage, but did hamper performance, as the high output cam profile would not engage properly. Toyota fixed the problem in late 2002, and there is a TSB for dealers showing what bolt to replace and the redesigned bolt.

Applications:

[edit] 3ZZ-FE

The 3ZZ-FE is the 1.6 L (1598 cc) version built in Japan. It is found in Asian Toyota Corolla Altis which is available in countries such as Singapore, Malaysia, Thailand and Taiwan. The entire exterior design and chassis is the same as the American Corolla. Bore is 79.0 mm and stroke is 81.5 mm. Max. Output is 109 hp (81kW) @ 6000 rpm. Max. Torque is 111 lb ft. of torque (150Nm) @ 3800 rpm.

Applications:

  • Toyota Corolla (Europe, 109hp)
  • Toyota Corolla Altis 1.6E (Asian, 110hp)

[edit] 4ZZ-FE

The 4ZZ-FE is a 1.4 L (1398 cc) version. Bore is 79.0 mm and stroke is 71.3 mm. Output is 95 hp (71 kW) at 6000 RPM with 96 ft·lbf (130 N·m) of torque at 4400 RPM.

Applications:

[edit] See also

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