Toyota 2ZZ-GE

The 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

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 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.

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 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

Author: Sergei Wers
About: Co-founder and CEO of a multi-brand auto repair shop (engine repair, chassis repair, body repair and painting) for over 15 years. I have been developing internet sites with technical specifications for more than seven years.