ZZ Brothers. - Двигатели 2ZZ-GE (англ.)

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2ZZ-GE

2ZZ-GE Engine in the Corolla XRS

Supercharged 2ZZ-GE installed in Lotus Elise SC

Disintegrated oil pump

The 2ZZ-GE is a 1.8 L (1796 cc or 109.6 in³) version built in Japan. Bore is 82 mm (3.23") and the stroke is 85 mm (3.35"). It uses MFI fuel injection, has VVTL-i, and features forged steel connecting rods. Compression ratio is 11.5:1, necessitating "premium" gasoline (91 octane or above in the(R+M)/2 scale used in North America^[4]). Power output for this engine varies depending on the vehicle and tuning, with the Celica, Corolla T-Sport ^[5]^[6], Lotus Elise and Lotus Exige offering 141 kW (189 hp) but the American versions of the 2003 Corolla, Matrix, and Pontiac Vibe versions only developing 180 hp^[4] with all later years offering anywhere from 173 hp in 2004 to 164 hp in 2006 due to a recurved powerband. The differing power numbers from 2004 through 2006 are due to changes in dynamometer testing procedures. The Australian variant Corolla Sportivo is 141 kW@7600 and 181N·m Torque. Due to noise regulations, Toyota recalled them for a flash of thePCM 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 225 hp (168 kW), while the Exige 240R's supercharger increases output to 240 hp (179 kW). The addition of a non-intercooled supercharger to the Elise SC produces 218 hp (163 kW) 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 as "lift") 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 timing in the American market. The table below lists the specifications of the two camshaft profiles. This is similar in concept to Honda's i-VTEC, but the two systems are very different in design and execution.

	Intake		Exhaust
	Duration	Valve lift	Duration	Valve lift
Low Cam	228°	7.6mm	228°	7.6mm
High Cam	292°	11.2mm	276°	10.0mm

Excluding the 2003 MR2 and European Celicas with the 1ZZ engine, the 2ZZ engine is also the only model in the ZZ engine family to use a six-speed manual transmission, as well as the only one to have been available with a four-speed Tiptronic-style automatic. These gearboxes were unique to this engine; since then, only a few Toyota engines have been paired with either a six-speed manual or a Tiptronic-style automatic (and only one other engine, the 4GR-FSE, has received both).

Toyota commissioned Yamaha to design the 2ZZ-GE and it shares several similarities with street bike engines, the most notable being the relatively high RPM design. The high-output cam profile is not activated until approximately 6,200 rpm (the exact point of engagement is different depending on the vehicle, year, and PCM involved) and will not engage until the engine is sufficiently warmed up to 60° celsius (140° fahrenheit). The Toyota PCM electronically limits RPM to about 8200 RPM (or 8400 RPM in some earlier cars) via fuel and/or spark cut. Just like the lift activation point, variations in rev-limit rpm exist between models. For example, Lotus 2ZZ-GEs are rev limited to 8500rpm whereas Celicas were rev limited to 7900 to 8200 rpm in North America, depending on the model year. Consequently, it's impossible to "over-rev" the engine with the throttle alone; a downshift from a higher gear must be involved. A typical "over-rev" can damage the oil pump, commonly disintegrating the lobe ring, resulting in damage similar to the picture at right. The oil pump is the Achilles heel of the 2ZZ, though incidents are rare and usually occur due to fault of the driver. Unfortunately, starving the engine of oil is almost always fatal to this particular engine design, even when caught quickly. CircuitWorx makes an aftermarket Oil Pump Gear that is recommended highly by TRD (Toyota Racing Development). Quote from Monkey Wrench Racing: "A CircuitWorx billet oil pump gear is much stronger than a stock gear and will withstand high RPM vibration much better than a stock unit."

The engine will easily run at speeds of around 4,000 rpm for extended periods of time and is designed to periodically run at the 8,400 RPM redline without issue. 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.

Also, 2004 and newer Matrix and Corolla XRS were sold with smog pumps and have an extra hole above each exhaust port in the engine head and manifold where the "air" is injected for complete fuel burning before the catalyst. It is of note that all 2ZZ-GE heads from 03/03 onwards carry this modification even if the vehicle does not have the air injection system.

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