Toyota 3ZZ-FE

The 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

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).

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.

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 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

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.