Toyota ZZ engine

2009-02-04T20:39:24Z

68.202.110.183: /* 1ZZ-FE */

The '''[[Toyota]] ZZ engine family''' is a [[straight-4]] [[piston engine]] series. The ZZ series uses an aluminum engine block and aluminum [[DOHC]] [[multivalve|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 ''[[Toyota A engine#4A|4A]]'' engines.

==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.<ref>http://www.spyderchat.com/1zzfe.pdf 1ZZ-FE SAE technical paper from Toyota</ref>

Applications:
* [[Toyota Corolla]]
* [[Chevrolet Prizm]]
* [[Pontiac Vibe]]
* [[Toyota Celica]]
* [[Toyota Matrix]]
* [[Toyota Avensis]]
* [[Toyota Wish]]
* [[Toyota MR2]]
* [[Lotus Elise]]

==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 features MFI [[fuel injection]], VVT-i, and light weight, cast aluminum rods.

Applications:
* [[Toyota Corolla]]
* [[Toyota Celica]] ''GT''
* [[Toyota MR2]] Spyder
* [[Toyota Wish]]1.8

==2ZZ-GE==
[[Image:Toyota_2ZZ-GE.JPG|thumb|200px|2ZZ-GE Engine in the Corolla XRS]]

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 utilizes MFI fuel injection, has VVTL-i, and features forged steel connecting rods. The compression ratio is 11.5:1, necessitating "premium" gasoline (91 octane or above in the [[Octane_rating#Measurement_methods|(R+M)/2 scale]] used in North America <ref>"Band Wagons" - ''Motor Trend'', Chris Walton. May 2002</ref>). Power output for this engine varies depending on the vehicle and tuning, with the [[Lotus Elise]] and [[Lotus Exige]] offering 190 hp but the 2003 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 and Celica GTS) is 141 kW@7600 RPM and 181 N·m of torque due to noise regulations. (Toyota recalled them for a flash of the [[Powertrain_Control_Module|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, while the Exige 240R's supercharger increases output to 240 hp.

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 [[Toyota GR engine|4GR-FSE]], has received both).

[[Image:2zzge_oil_pump_lobes.jpg|thumb|200px|Disintegrated oil pump]]

Toyota commissioned Yamaha to design the 2ZZ-GE and it shares several similarities with [[Sportbike|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 [[Technical_Service_Bulletin|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 [[Secondary_air_injection|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, 189 hp/180 Nm)
* [[Toyota Corolla]] ''TS'' (Europe, 192 PS)
* [[Toyota Corolla]] ''Compressor '' (Europe, 225 PS)
* [[Toyota Corolla]] ''XRS'' (USA, 164 hp)
* [[Toyota Corolla|Toyota Corolla Fielder]] ''Z Aero Tourer'' (Japan, 190 PS)
* [[Toyota Corolla|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)
* [[Lotus Exige]] (US/UK, 190 hp & 243 hp supercharged)

==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 mm and the stroke is 81.5 mm. Maximum output is 109 hp (81 kW) @ 6000 RPM. Max torque is 111 ft-lb 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 @ 6000 Kw and 146 @ 4400 Nm)

==4ZZ-FE==
The 4ZZ-FE is a 1.4 L (1398 cc) version. Bore is 79 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 ===
{{reflist}}
* Citations of use in the 1ZZ-FE in the Toyota MR2: [http://www.sportcompactcarweb.com/projectcars/0610sccp_project_mr2_spyder/][http://www.toyotaimportsforum.co.uk/mr2/mrcmodels.htm]

==See also==

* [[List of Toyota engines]]
* [http://www.toysport.com/Technical%20Information/2ZZ-GE_tech_notes.htm ZZ-GE Tech Notes]

[[Category:Toyota engines|ZZ]]

Wikicars - User contributions [en]

Toyota ZZ engine