Toyota 2ZZ-GE

Toyota 2ZZ-GEThe Toyota 2ZZ-GE is a 1.8 l (1795 cc, 109.5 cu·in) straight-four 4-stroke natural aspirated gasoline engine from Toyota ZZ-family. The 2ZZ-GE engine was manufacturerd on Shimoyama Plant from 1999 to 2011.

The 2ZZ-GE engine features a die-cast aluminum engine block with cast-iron cylinder liners. This engine used Metal Matrix Composite (MMC) cylinder walls for linerless construction. The 2ZZ-GE has an aluminum cylinder head with two overhead camshafts (DOHC) and four valves per cylinder (16 in total), Multipoint fuel injection system, VVTL-i (Intelligent variable valve timing with lift), and distributorless, coil-on-plug “Toyota Direct Ignition” system.

The cylinder bore is 82.0 mm (3.23 in) and the piston stroke is 85.0 mm (3.35 in). Compression ratio rating is 11.5:1. The Toyota 2ZZ-GE motor produced from 166 PS (122 kW; 164 HP) at at 7,600 rpm to 192 PS (141 kW; 189 HP) at 7,600 rpm to of maximum horsepower and from 141 N·m (14.4 kg·m, 103.9 ft·lb) at 7,800 rpm to 230 N·m (23.5 kg·m, 169.5 ft·lb) at 6,800 rpm of peak torque.

The breakdown of the engine code is as follows:

  • 2 – 2-nd generation engine
  • ZZ – Engine family
  • G – Performance wide-angle DOHC
  • E – Multi-Point Fuel Injection

General information

Engine Specifications
Engine code2ZZ-GE
LayoutFour stroke, Inline-4 (Straight-4)
Fuel typeGasoline (petrol)
Production1999-2011
Displacement1.8 L, 1,794 cm3 (109.5 cu in)
Fuel systemMulti-Point Fuel Injection
Power adder
Power output From 166 PS (122 kW; 164 HP) at 7,600 rpm
to 192 PS (141 kW; 189 HP) at 7,600 rpm
Torque output From 141 N·m (14.4 kg·m, 103.9 ft·lb) at 7,800 rpm
to 230 N·m (23.5 kg·m, 169.5 ft·lb) at 6,800 rpm
Firing order1-3-4-2
Dimensions (L x W x H):
Weight115 kg (253.5 lbs)

Cylinder block

The Toyota 2ZZ-GE has an aluminum cylinder block and five bearing support system. The high pressure cast aluminum alloy engine block used Metal Matrix Composite (MMC) reinforced cylinder walls. MMC is a reinforcement material composed of ceramic parts and fibers. The Toyota 2ZZ engine has an 82.0 mm (3.23 in) cylinder bore and 85.0 mm (3.35 in) piston stroke. Compression ratio rating is 11.5:1.

The 2ZZ-GE engine utilized a forged crankshaft that had five journals and eight balance weights. To reduce reciprocating mass and friction, the 2ZZ-GE engine has lightweight connecting rods which featured nutless-type plastic region tightening bolts.

The engine is equipped with aluminum alloy pistons with two compression and single oil control ring. The pistons were internally cooled by oil jets and used full floating-type piston pins.

Cylinder block
Cylinder block alloyAluminium
Compression ratio:11.5:1
Cylinder bore:82.0 mm (3.23 in)
Piston stroke:85.0 mm (3.35 in)
Number of piston rings (compression / oil):2/1
Number of main bearings:5
Cylinder inner diameter (standard):82.000-82.013 mm (3.2283-3.2289 in)
Piston skirt diameter (standard):81.975-81.993 mm (3.2274-3.2281 in)
Piston pin outer diameter:20.004-20.007 mm (0.7875-0.7876 in)
Piston ring side clearance:Top0.030-0.070 mm (0.0012-0.0028 in)
Second0.030-0.070 mm (0.0012-0.0028 in)
Piston ring end gap:Top0.250-0.350 mm (0.0098-0.0138 in)
Second0.350-0.500 mm (0.0138-0.0197 in)
Crankshaft journal diameter:47.988-48.000 mm (1.8893-1.8898 in)
Crankpin diameter:44.992-45.000 mm (1.7713-1.7717 in)

Cylinder head

The cylinder head is made of aluminum alloy which gives it good cooling efficiency. The engine has dual overhead camshaft design with four valves per cylinder. The camshaft is driven by the single roller chain (pitch 8 mm) with the outer hydraulic tensioner and lubrication nozzle.

The 2ZZ-GE used VVTL-i (Intelligent variable valve timing with lift). To variable inlet valve timing, the 2ZZ-GE engine used a variable valve lift system operated on the inlet and exhaust valves. At engine speeds above 6000 rpm, high-lift camshaft profiles are engaged and the cam lobes increased intake lift from 7.25 to 11.2 mm and exhaust lift from 7.25 mm to 10.0 mm). The intake valves have a 34.0 mm (1.34 in) diameter and the exhaust valves have a 29.0 mm (1.14 in) diameter.

Cylinder head
Valve Arrangement:DOHC, chain drive
Valves:16 (4 valves per cylinder)
Valve head diameter:INTAKE34.0 mm (1.3386 in)
EXHAUST29.0 mm (1.1417 in)
Valve length:INTAKE111.30 mm (4.3819 in)
EXHAUST111.70 mm (4.3976 in)
Valve stem diameter:INTAKE5.470-5.485 mm (0.2153-0.2159 in)
EXHAUST5.445-5.470 mm (0.2144-0.2154 in)
Valve spring free length: Intake: 46.42 mm (1.8276 in)
Exhaust: 46.50 mm (1.8307 in)
Camshaft cam height:INTAKE 1: 40.607-40.707 mm (1.5987-1.6026 in)
2: 38.769-38.869 mm (1.5263-1.5303 in)
EXHAUST 1: 40.019-40.119 mm (1.5755-1.5795 in)
2: 38.863-38.963 mm (1.5300-1.5340 in)
Outer camshaft journal diameter:№134.449-34.465 mm (1.3563-1.3569 in)
Other journals diameter22.949-22.965 mm (0.9035-0.9041 in.)

Head tightening procedure and torque specs:

  • Step 1: 35 Nm; 3.6 kg·m; 26 ft·lb
  • Step 2: Turn all bolts 90°
  • Step 3: Turn all bolts another 90°

Maintenance data

Valve clearance
Intake valve0.10-0.16 mm (0.0039-0.0063 in)
Exhaust valve0.24-0.30 mm (0.0094-0.0118 in)
Compression pressure
Standard14.3 kg/m2 / 350 rpm
Minimun10.2 kg/m2 / 350 rpm
Compression differential limit between cylinders0.6 kg/m2 / 350 rpm
Oil system
Oil consumption , L/1000 km (qt. per miles)up to 0.5 (1 qt. per 1200 miles)
Recommended engine oil10W-30
Oil type APISH or SJ
Engine oil capacity (Refill capacity) With oil filter: 4.4 L
Without oil filter: 4.2 L
Oil change interval, km (miles)10,000 (6,000)
Oil pressure Idle spped: 0.3 kg/cm3
At 3,000 rpm: 3.0 kg/cm3
Ignition system
Idle speed750-800 rpm
Spark plug DENSO: SK20R11 or NGK: IFR6A11
Spark plug gap1.0-1.1 mm (0.0394-0.0433 in)
Spark plug torque18 N·m (1.8 kg·m, 13.3 ft·lb)

Valve clearance adjustment data

Calculate the thickness of new adjusting valve lifter so valve clearance comes within specified values.

R = Thickness of removed valve lifter
N = Thickness of new valve lifter
M = Measured valve clearance

Intake:
N = R + [M – 0.13 mm (0.005 in)]
Exhaust:
N = R + [M – 0.25 mm (0.010 in)]

Valve lifters are available in 41 sizes to range from 2.00 mm (0.0787 in) to 2.80 mm (0.1102 in), in steps of 0.02 mm (0.0008 in).

Vehicle applications

ModelYears Produced
Toyota Celica
Toyota Corolla
Toyota Corolla Runx / Fielder
Toyota Matrix
Pontiac Vibe
Toyota Voltz
Toyota WiLL VS
Lotus Elise
Lotus Exige
Lotus 2-Eleven
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