Toyota 3ZZ-FE

Toyota 3ZZ-FEThe Toyota 3ZZ-FE is a 1.6 l (1,598 cc, 97.52 cu-in) straight-four 4-stroke natural aspirated gasoline engine from Toyota ZZ-family.

The 3ZZ-FE engine features a die-cast aluminum engine block with thin press-fit cast iron cylinder liners and aluminum cylinder head with two overhead camshafts (DOHC) and four valves per cylinder (16 in total). The Toyota 3ZZ-FE engine used Multipoint fuel injection system, VVT-i (Variable Valve Timing with intelligence). The is equipped with DIS-4 – with individual ignition coil for each spark plug.

Compression ratio rating is 10.5:1. Bore and stroke are 79.0 mm (3.11 in) and 81.5 mm (3.21 in), respectively. The engine produced 110 PS (81 kW; 109 HP) at 6,000 rpm of maximum horsepower and 150 Nm (15.3 kg·m; 110.7 ft·lb) at 3,800 rpm of peak torque.

The breakdown of the engine code is as follows:

  • 3 – 3-rd generation engine
  • ZZ – Engine family
  • F – Economy narrow-angle DOHC
  • E – Multi-Point Fuel Injection

General information

Engine Specifications
Engine code3ZZ-FE
LayoutFour stroke, Inline-4 (Straight-4)
Fuel typeGasoline (petrol)
Production1998-2007
Displacement1.6 l, 1,598 cm3, (97.52 cu-in)
Fuel systemMulti-Point Fuel Injection
Power adder
Power output 110 PS (81 kW; 109 HP) at 6,000 rpm
Torque output 150 Nm (15.3 kg·m; 110.7 ft·lb) at 3,800 rpm
Firing order1-3-4-2
Dimensions (L x W x H):
Weight

Cylinder block

The Toyota 3ZZ-FE has an aluminum “open deck” cylinder block with thin-walled cast-iron liners and five bearing support system. The liners are fused into the block and their special rough outer surface promotes strong connection. The Toyota 3ZZ has a 79.0 mm (3.11 in) cylinder bore and 81.5 mm (3.21 in) piston stroke. Compression ratio rating is 10.5:1.

The engine is equipped with aluminum alloy pistons with two compression and single oil control ring. The pistons are connected to the rods with full-floating pins. The connecting rod caps are mounted by bolts (without nuts).

Cylinder block
Cylinder block alloyAluminium
Compression ratio:10.5:1
Cylinder bore:79.0 mm (3.11 in)
Piston stroke:81.5 mm (3.21 in)
Number of piston rings (compression / oil):2 / 1
Number of main bearings:5
Cylinder inner diameter (standard):79.000-78.013 mm (3.1102-3.1107 in)
Piston skirt diameter (standard):78.955-78.965 mm (3.1085-3.1089 in)
Piston pin outer diameter: 20.004-20.013 mm (0.7875-0.7879 in)
Piston ring side clearance:Top0.020-0.070 mm (0.0008-0.027 in)
Second0.030-0.070 mm (0.0012-0.0028 in)
Piston ring end gap:Top0.25-0.35 mm (0.0098-0.0138 in)
Second0.35-0.50 mm (0.0138-0.0197 in)
Crankshaft journal diameter:47.988-48.000 mm (1.8893-1.8892 in)
Crankpin diameter:43.992-44.000 mm (1.7319-1.7323 in)

Crankcase bolts tightening procedure and torque specs (M10):

  • Step 1: 22 Nm; 2.2 kg·m; 16.2 ft·lb
  • Step 2: 44 Nm; 4.5 kg·m; 32.5 ft·lb
  • Step 3: Turn all bolts 45°
  • Step 4: Turn all bolts another 45°

After securing bearing cap bolts, make sure crankshaft turns smoothly by hand.

Connecting rod bearing bolts

  • Step 1: 20 Nm (2.04 kg·m; 14.76 ft·lb)
  • Step 2: Turn bolts 90°

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 engine has a conical type combustion chamber. The camshaft is driven by the single roller chain (pitch 8 mm) with the outer hydraulic tensioner.

The 3ZZ-FE used Variable Valve Timing with intelligence system (VVT-i) on the intake camshaft. Intake valves are 32.0 mm (1.2598 in) in diameter, and the exhaust valves are 27.5 mm (1.0827 in). The engine did not have hydraulic lifters, so special valve shims were used to adjust the valve clearance.

Cylinder head
Valve Arrangement:DOHC, chain drive
Valves:16 (4 valves per cylinder)
Valve head diameter:INTAKE32.0 mm (1.2598 in)
EXHAUST27.5 mm (1.0827 in)
Valve length:INTAKE88.65 mm (3.4901 in)
EXHAUST88.69 mm (.4917 in)
Valve stem diameter:INTAKE5.470-5.485 mm (0.2153-0.2159 in)
EXHAUST5.465-5.480 mm (0.151-0.2157 in)
Valve spring free length:43.40 mm (1.7086 in)
Camshaft cam height:INTAKE44.333-44.433 mm (1.7454-1.7493 in)
EXHAUST43.761-43.861 mm (1.7229-1.7268 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: 49 Nm; 5 kg·m; 36.16 ft·lb
  • Step 2: Turn all bolts 90°

Maintenance data

Valve clearance
Intake valve0.15-0.25 mm (0.006-0.010 in)
Exhaust valve0.25-0.35 mm (0.010-0.014 in)
Compression pressure
Standard13.3 kg/m2 / 200 rpm
Minimun10.2 kg/m2 / 200 rpm
Compression differential limit between cylinders0.6 kg/m2 / 200 rpm
Oil system
Oil consumption , L/1000 km (qt. per miles)up to 0.5 (1 qt. per 1200 miles)
Recommended engine oil5W-30, 10W-30
Oil type APISJ or higher
Engine oil capacity (Refill capacity)3.7 L (3.9 US. qt.)
Oil change interval, km (miles)5,000-10,000 (3,000-6,000)
Oil pressure Idle spped: 0.3 kg/cm3
At 3,000 rpm: 3.0-5.5 kg/cm3
Spark plug DENSO: K16R-U11 or NGK: BKR5EYA11
Spark plug gap1.1 mm (0.043 in)
Spark plug torque25 Nm (2.5 kg·m; 18.0 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 – 0.20 mm (0.008 in)]
Exhaust:
N = R + [M – 0.30 mm (0.012 in)]

Valve lifters are available in 35 sizes to range from 5.06 mm (0.1992 in) to 5.74 mm (0.2259 in), in steps of 0.02 mm (0.0008 in).

Example (intake valve):
R = 5.10 mm
M = 0.52 mm
N = 5.10 + (0.52 – 0.20) = 5.42 mm.

Vehicle applications

ModelYears Produced
Toyota Corolla
Toyota Corolla Altis
Toyota Corolla RunX 160
Toyota Corolla XLi
Toyota Avensis
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2 Comments

  1. I have Toyota Corolla 2010 Model GCC Specs with 3ZZ Engine,I am Facing problem on cool starting the Engine Knocking, Missing and suddenly off but once its get worm with Manual Acceleration than become okay

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