Toyota ZZ engine

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.

The seemingly complicated names Toyota gives its engines is actually quite simple. The first number denotes the engine block's generation. The next one or two letters, followed by a hyphen, specify the engine family. The remaining letters following the hyphen list the engine's features. For example, the 2ZZ-GE can be decoded as being the second generation of the ZZ engine series and features a performance head - wide angle valves (G) and Electronic Fuel Injection (E). [http://toyotacelicaonline.com/engine.htm Toyota Celica Online - Engine Number]

"More information on Toyota engines and how to read their names can be found here."

1ZZ-FE

The 1ZZ-FE is a 1.8 L (1794 cc) version built in Buffalo, 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. [http://www.spyderchat.com/1zzfe.pdf 1ZZ-FE SAE technical paper from Toyota]

Applications:
* Toyota Corolla CE/LE/S
* Chevrolet Prizm
* Pontiac Vibe
* Toyota Celica GT
* Toyota Matrix XR
* Toyota Avensis
* Toyota Wish
* Toyota MR2
* Lotus Elisecite web | url = http://www.grouplotus.com/cars/showroom.html#/elise/eliseS/eliseS_vehicle_des.html | title = Lotus Elise S - Vehicle Description | accessdate = 2008-06-24 | publisher = Group Lotus PLC ]

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:
* Toyota Corolla
* Toyota Celica "GT"
* Toyota MR2 Spyder
* Toyota Wish1.8

2ZZ-GE

The 2ZZ-GE is a 1.8 L (1796 cc or 109.6 in³) version built in Japan. Bore is 82 mm (3.23") and the stroke is 85 mm (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 "The Next Band Wagons" - "Motor Trend", Chris Walton. May 2002] ). Power output for this engine varies depending on the vehicle and tuning, with the Toyota Celica, Toyota Corolla T-Sport [http://www.zeperfs.com/fiche367.htm] [http://web.archive.org/web/20050509154910/motor.terra.es/motor/contactos/c_ficha.cfm?id=MOT21278 ] , Lotus Elise and Lotus Exige offering Convert|141|kW|hp|0|abbr=on but the American versions of the2003 Toyota Corolla, Toyota Matrix, and Pontiac Vibe versions 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 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 Convert|225|hp|kW|0|abbr=on, while the Exige 240R's supercharger increases output to Convert|240|hp|kW|0|abbr=on.

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. The table below lists the specifications of the camshafts. 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).

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:
* Toyota Celica "SS-II" (Japan, 190 PS)
* Toyota Celica "GT-S" (USA, 180 hp)
* Toyota Celica "190"/"T-Sport" (UK, 189 hp)
* Toyota Corolla "Sportivo" (Australia, Convert|189|hp|kW|0|abbr=on/180 Nm)
* Toyota Corolla "TS" (Europe, 192 PS)
* Toyota Corolla "Compressor " (Europe, 225 PS)
* Toyota Corolla "XRS" (USA, 164/170 hp)
* Toyota Corolla Fielder "Z Aero Tourer" (Japan, 190 PS)
* Toyota Corolla Runx "Z Aero Tourer" (Japan, 190 PS)
* Toyota Matrix "XRS" (USA, 164-180 hp)
* Pontiac Vibe "GT" (USA, 164-180 hp)
* Lotus Elise (North America/UK, 190 hp)cite web | url = http://www.grouplotus.com/cars/showroom.html#/elise/eliseR/eliseR_vehicle_des.html | title = Lotus Elise R - Vehicle Description | accessdate = 2008-06-24 | publisher = Group Lotus PLC ]
* Lotus Exige (US/UK, 190 hpcite web | url = http://www.edmunds.com/insideline/do/Drives/FullTests/articleId=115908 | title = Full Test: 2006 Lotus Exige | accessdate = 2008-06-24 | author = Chris Walton | date = 2006-06-28 | publisher = Edmunds Inc. ] & 243 hp [supercharged] cite web | url = http://www.motortrend.com/roadtests/coupe/112_0702_2007_lotus_exige_s | title = Newcomers: 2007 Lotus Exige S | accessdate = 2008-06-24 | author = Greg N. Brown | work = MotorTrend | publisher = Source Interlink Media, Inc. ] )

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 Auto ft.lb|111|0. of torque (150 Nm) @ 3800 rpm.

Applications:
* Toyota Corolla (Europe, 109 hp)
* Toyota Corolla Altis "1.6E" (Asian, 110 hp)
* Toyota Corolla and RunX "160" (South African, 81 @ 6000Kw and 146 @ 4400Nm)

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:
* Toyota Corolla
* Toyota Auris

References

External links

* [http://zz-series.com/phpBB-3.0.1/phpBB3/index.php ZZ-Series Engines Forum]
* [http://www.toysport.com/Technical%20Information/2ZZ-GE_tech_notes.htm ZZ-GE Tech Notes]