| Toyota ZZ engine | |
| Manufacturer: | Toyota |
| Supercharger: | TRD (some versions) |
| Production: | 1997–2008 |
| Predecessor: | A engine |
| Successor: | ZR engine (for 1ZZ and 2ZZ series) |
| Configuration: | Straight-4 |
| Displacement: | 1398cc 1598cc 1794cc 1796cc |
| Bore: | 792NaN2 822NaN2 |
| Stroke: | 71.32NaN2 81.52NaN2 852NaN2 91.5mm |
| Block: | Aluminium, Cast iron |
| Head: | Aluminium |
| Valvetrain: | DOHC 4 valves x cyl. with VVT-i and VVTL-i (some versions) |
| Fuelsystem: | Multi-point fuel injection |
| Compression: | 10.0:1, 11.5:1 |
| Fueltype: | Gasoline |
| Coolingsystem: | Water-cooled |
The Toyota ZZ engine family is a straight-4 piston engine series. The ZZ series uses a die-cast aluminium engine block with thin press-fit cast iron cylinder liners, and aluminium DOHC 4-valve cylinder heads.[1] The 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 optimised for economy, with torque emphasised in lower revolutions per minute operating range, while the latter is a "square" design optimised for high-RPM torque, yielding higher peak power. The ZZ family replaced the extremely popular cast-iron block 4A engines.
Toyota engine names are interpreted as follows. The leading number denotes the generation, and the next one or two letters, specify the engine family. The remaining letters, following a hyphen, describe the engine's major features. For example, the 2ZZ-GE can be decoded as being the second generation of the ZZ engine series and features a performance-oriented cylinder head with widely angled valves (G) and electronic fuel injection (E).[2]
The 1ZZ-FE is a 1794cc version built in Buffalo, West Virginia. Bore X stroke of NaNmm. Compression ratio is 10.0:1. Output is between 1200NaN0 at 5,600 rpm with 165abbr=on0abbr=on of torque at 4,400 rpm, and 1300NaN0 at 6,400 rpm with 171abbr=on0abbr=on of torque at 4,200 rpm. It uses MPFI, has VVT-i (1998-99 1ZZ engines don't have VVT-i), and features fracture-split forged powder metal connecting rods, one-piece cast camshafts, and either a cast aluminum intake manifold or a molded plastic intake manifold.[3] [4]
A factory supported bolt-on supercharger kit was sold for the 2003–2004 Corolla and Matrix by Toyota Racing Development, and Pontiac Vibe by GM Performance. The supercharger gives 7.5psi of boost, with a 40hp and 380NaN0 of torque increase at the wheels.[5]
Its production in Cambridge, Ontario was discontinued in December 2007.
Applications:
Toyota announced a voluntary recall of 2005 to 2008 Toyota Corollas and Matrixes equipped with 1ZZ-FE engines. The issue involves the engine control module, and includes the potential for it to develop a crack on the module's circuit board, which can result in the car not starting, the transmission shifting harshly, or the engine stalling. Additionally, General Motors announced a voluntary recall of Pontiac Vibes from years 2005 to 2008 for the same issue.
The 1ZZ-FED is similar to the 1ZZ-FE but is built separately in the Shimoyama plant. Toyota's advertised power output is at 6,400 rpm and of torque at 4,400 rpm. It uses Multi-point fuel injection, VVT-i[6] and has larger 32mm intake valves and 27.5mm exhaust valves with corresponding revisions to the ports, resulting in higher power output compared to the 2002-2008 1ZZ-FE.
Applications:
Special modified 1ZZ-FE that can run on E100 Ethanol.
Applications:
Internal code of 1ZZ-FE engine for SAIC-GM-Wuling cars.[7] [8]
Applications:
The 2ZZ-GE is a version built in Japan, in collaboration with Yamaha Motor Corporation. Bore x stroke is NaNmm. It uses Multi-point Fuel Injection, VVTL-i, and features forged steel connecting rods. Compression ratio is 11.5:1, necessitating high-octane gasoline (91 octane or above in the (R+M)/2 scale used in North America[9]). Power output for this engine varies depending on the vehicle and tuning, with the Celica GT-S, Corolla T-Sport,[10] [11] Lotus Elise and Lotus Exige offering 1410NaN0, whereas the American versions of the 2003 Matrix and Pontiac Vibe versions produce 180hp @ 7,600 rpm[9] and 1300NaN0 @ 6800 rpm, with all later years offering anywhere from 173hp in 2004 to 164hp in 2006 due to a recurved powerband. The differing power figures from 2004 through 2006 are due to changes in dynamometer testing procedures. The Australian variant Corolla Sportivo produces 141kW at 7,600 rpm and 181Nm of 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 with intercooler to achieve 2250NaN0, while the Exige 240R's supercharger increases output to 2400NaN0. The addition of a non-intercooled supercharger to the Elise SC produces 2180NaN0 with a considerable weight saving. The supercharged engines are not labeled 2ZZ-GZE.
Unique to the ZZ family, the 2ZZ-GE utilizes a dual camshaft profile system (the "L" in VVTL-i, known by enthusiasts and engineers alike as "lift" similar to Honda's VTEC) to produce the added power without an increase in displacement or forced induction. The 2ZZ-GE was the first production engine to combine cam-phasing variable valve timing with dual-profile variable valve lift in the American market. The table below lists the specifications of the two camshaft profiles.
| Intake | Exhaust | ||||
|---|---|---|---|---|---|
| Duration | Valve lift | Duration | Valve lift | ||
| Low Cam | 228° | 7.6mm | 228° | 7.6mm | |
| High Cam | 292° | 11.2mm | 276° | 10mm | |
For the first few years of production, the engines were notorious for failing "lift bolts". This did not 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.
The 2004 and newer Matrix and Corolla XRS models were equipped with smog pumps and have an extra hole above each exhaust port in the engine head and manifold where air is injected to achieve complete fuel burning before the exhaust stream reaches the catalyst. All 2ZZ-GE heads from 03/03 onwards carry this modification even if the vehicle does not have the air injection system.
The high-pressure die-cast aluminum alloy engine block of the 2ZZ-GE featured Metal Matrix Composite (MMC) reinforced cylinder walls. MMC is a reinforcement material composed of ceramic parts and fibers.
The 2ZZ-GE is still one of the highest output per liter and the highest revving mass production engines ever made. In recognition of its incredible power output, the 2ZZ-GE engine has won the International Engine of the Year category for 1.4 to 1.8-liter engines in 2002
Applications:
The 3ZZ-FE is a 1598cc engine unit built in Japan for models built from 2000 to 2012. Bore and stroke is NaNmm. Max. output is 1090NaN0 at 6,000 rpm and max. torque is 1500NaN0 at 4,400 rpm. It features SMP pistons which Toyota made in 1ZZ-FE engines. The preferred engine oil is 5W-30 API grade SL/SM.
It is found in the Toyota Corolla Altis which is sold in Asian countries such as Singapore, Malaysia, Philippines, Thailand, Pakistan (as SE Saloon) and Taiwan; the Toyota Corolla EX in China up until the late 2000s; the Toyota Corolla sedan, hatchback and station wagon sold in Sri Lanka, parts of Europe and the Middle East; and the Toyota Corolla XLi sedan in Brazil. In South Africa, the motor can be found in the RunX 160 and Corolla 160.
Applications:
The 4ZZ-FE is a 13981NaN1 version. Bore and stroke is NaNmm. Output is 970NaN0 at 6000 rpm with 1300NaN0 of torque at 4400 rpm.
Applications: