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.

Contents

[edit] 1ZZ-FE

The 1ZZ-FE is a 1.8 L (1794 cc) version built in Buffalo and West Virginia. Its production in Cambridge, Ontario was discontinued in December 2007. Bore is 79 mm and stroke is 91.5 mm. Output is 126 hp (97 kW) at 6000 rpm with 125 ft·lb (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 either a cast aluminum intake manifold or a molded plastic one.[1]

Applications:

[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·lb (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 (1796cc or 109.6 in³) version built in Japan. Bore is 82mm (3.23") and the stroke is 85mm (3.35"). It uses MFI fuel injection, has VVTL-i, and features forged steel connecting rods. Compression ratio is 11.5:1, necessitating "premium" gasoline (91 octane or above in the (R+M)/2 scale used in North America[2]). Power output for this engine varies depending on the vehicle and tuning, with the Lotus Elise and Lotus Exige offering 190 hp (142 kW) but the 2003 Toyota Corolla, Toyota Matrix, and Pontiac Vibeversions only developing 180 hp with all later years offering anywhere from 173 hp in 2004 to 164 hp in 2006 due to a recurved powerband. The differing power numbers from 2004 through 2006 are due to changes in dynamometer testing procedures. The Australian variant (Corolla Sportivo and Celica GTS) is 141 kW@7600 and 181N·m Torque due to noise regulations. (Toyota recalled them for a flash of the PCM to up their output to classify them in the more lenient "sports car" noise category.) The Corolla Compressor and Lotus Exige S add a supercharger to achieve 225 hp (168 kW), while the Exige 240R's supercharger increases output to 240 hp (179 kW).

Unique to the ZZ family, 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. This is similar in concept to Honda's i-VTEC, but the two systems are very different in design and execution.

Excluding the 2003 MR2, the engine is also the only model in the ZZ engine family to use a six-speed manual transmission, as well as the only one to have been available with a four-speed Tiptronic-style automatic. 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 other 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 approximately 6,200 rpm (the exact point of engagement is different depending on the vehicle, year, and PCM involved) and will not engage until the engine is sufficiently warmed up. The Toyota PCM electronically limits RPM to about 8200 RPM (or 8400 RPM in some earlier cars) via fuel and/or spark cut. Consequently, it's impossible to "over-rev" the engine with the throttle alone; a downshift from a higher gear must be involved. A typical "over-rev" can damage the oil pump, commonly disintegrating the lobe ring, resulting in damage similar to the picture at right. The oil pump is the Achilles heel of the 2ZZ, though incidents are rare and usually occur due to fault of the driver. Unfortunately, starving this particular design of oil is almost always fatal to the engine, even when caught quickly.

The engine will easily run at speeds of around 4,000 rpm for extended periods of time and is designed to periodically run at the 8,400 RPM redline without issue. For the first few years of production, the engines were notorious for failing "lift bolts". This didn't damage the engine, but would hamper performance, as the high output cam profile was unable to properly engage. Toyota fixed the problem in late 2002 with a redesigned bolt that was installed on later engines. Earlier engines with the problematic bolts can be fixed via a Toyota-issued TSB simply requiring the new bolt to be installed in place of the old one.

Also, 2004 and newer Matrix and Corolla XRSes were sold with smog pumps and have an extra hole in the engine block and header where the "air" is extracted for induction into the intake.

Applications:

[edit] 3ZZ-FE

The 3ZZ-FE is a 1.6 L (1598 cc) incarnation built in Japan. It is found in the Asian Toyota Corolla Altis which is available in countries such as Singapore, Malaysia, Philippines, Thailand and Taiwan and in the Toyota Corolla sedan sold in Sri Lanka. In South Africa the motor can be found in the Rux 160 and Corolla 160. The entire exterior design and chassis is the same as the American Corolla. Bore is 79.0 mm and the stroke is 81.5 mm. Max. output is 109 hp (81 kW) @ 6000 rpm. Max. torque is Template:Auto ft.lb. of torque (150 Nm) @ 3800 rpm.

Applications:

[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·lb (130 N·m) of torque at 4400 rpm.

Applications:

[edit] References

  1. ^ http://www.spyderchat.com/1zzfe.pdf 1ZZ-FE SAE technical paper from Toyota
  2. ^ "Band Wagons" - Motor Trend, Chris Walton. May 2002
  • Citations of use in the 1ZZ-FE in the Toyota MR2: [1][2]


[edit] See also

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