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EG-2 – 2ZR-FE ENGINE

ENGINE

2ZR-FE ENGINE

JDESCRIPTION D The newly developed 2ZR-FE engine is an in-line 4-, 1.8-liters, 16- DOHC engine. D This engine uses the Dual VVT-i (Variable -intelligent) system, DIS (Direct ) and ETCS-i (Electronic Control System-intelligent). They have been developed to realize high performance and fuel economy, and reduce exhaust emission.

04FEG104Y

04FEG103Y ENGINE – 2ZR-FE ENGINE EG-3

" Engine Specifications A

No. of Cyls. & Arrangement 4-cylinder, In-line Valve Mechanism 16-valve DOHC, Chain Drive (with Dual VVT-i) Pentroof Type Manifolds Cross-flow Fuel System SFI Displacement cm3 (cu. in.) 1798 (109.7) × mm (in.) 80.5 × 88.3 (3.17 × 3.48) 10.0 : 1 98 kW @ 6000 rpmrpm MaxMax. Output*1 (SAE(SAE-NET) NET) (132 HP @ 6000 rpm) 174 N.m @ 4400 rpmrpm MaxMax. Torque* 1 (SAE(SAE-NET) NET) (128 ft.lbf @ 4400 rpm) Open 1_ – 56_ BTDC Close 65_ – 10_ ABDC Valve Timing Open 51_ – 11_ BBDC Exhaust Close 3_ – 43_ ATDC 1 – 3 – 4 – 2 Octane Rating 87 or higher Oil Grade ILSAC Tailpipe Emission Regulation ULEV-II, SFTP Evaporative Emission Regulation LEV-II, ORVR Engine Service Mass*2 (Reference) 117 kg (257.9 lb) *1: Maximum output and torque ratings are determined by revised SAE J1349 standard. *2: Weight shows the figure with oil and water fully filled. EG-4 ENGINE – 2ZR-FE ENGINE

" Valve Timing A

: Intake Valve Opening Angle : Exhaust Valve Opening Angle Intake VVT-i TDC Operation Range 1_ 3_ 43_ 56_

65_ 51_

Exhaust VVT-i 10_ 11_ BDC Operation Range

00SEG124Y

" Performance Curve A

110 140 180 100 130 130 170 120 90 160 120 110 80 Torque 150 110 100 70 N.m (lb-ft) 140 90 100 130 80 60 Output 120 90 (HP) kW 70 50 110 80 60 100 50 40 40 30 30 20 20 10 10 0 1000 2000 3000 4000 5000 6000 7000

Engine Speed (rpm) 08SEG28Y ENGINE – 2ZR-FE ENGINE EG-5

JFEATURES OF 2ZR-FE ENGINE The 2ZR-FE engine has been able to achieve the following performance through the use of the items listed below. (1) High performance and fuel economy (2) Low noise and vibration (3) Lightweight and compact design (4) Good serviceability (5) Clean emission

Item (1) (2) (3) (4) (5) A cylinder block made of aluminum alloy is used. f Spiny liners are used. f Engine Proper The skirt portion of the has a resin coating f f f applied to reduce friction. Low tension piston rings are used. f f A timing chain and a chain tensioner are used. f f VlValve Hydraulic lash adjusters are used. f f MechanismMechanism Roller rocker arms are used. f f f TOYOTA Genuine SLLC (Super Long Life Coolant) Cooling System f is used. A charcoal filter is used in the air cleaner cap. f An intake manifold made of plastic is used. f Intake and An upright intake port is used. f A stainless is used. f f The TWCs (Three-Way Catalytic converters) are f used on the exhaust pipe. A fuel returnless system is used. f f f Fuel System Quick connectors are used to connect the fuel hose f with the fuel pipe. The DIS (Direct Ignition System) makes ignition f f f timing adjustment unnecessary. Ignition System Long-reach, thin-electrode type iridium tipped spark f f f plugs are used. Charging System A segment conductor type generator is used. f f Serpentine A serpentine belt drive system is used. f f f Drive System MRE (Magnetic Resistance Element) type f position sensors are used. The ETCS-i (Electronic Throttle Control f Engine Control System-intelligent) is used. System The Dual VVT-i (-intelligent) f f is used. The control (cranking hold function) is used. f EG-6 ENGINE – 2ZR-FE ENGINE

JENGINE PROPER

1. Cover D Lightweight and high-strength aluminum die-cast cylinder head cover is used. D An oil delivery pipe is installed inside the cylinder head cover. This ensures lubrication to the sliding parts of the roller , improving reliability.

Cylinder Head Cover Oil Delivery Pipe

A

View from A Cylinder Head Cover 04FEG50Y

2. Cylinder A triple-layer metal type cylinder head gasket is used.

Front AA

A – A Cross Section 008EG09Y ENGINE – 2ZR-FE ENGINE EG-7

3. Cylinder Head and Camshaft Housing D The cylinder head structure has been simplified by separating the camshaft housing ( journal portion) from the cylinder head. D The cylinder head, which is made of aluminum, contains a pentroof type combustion chamber. The is located in the center of the combustion chamber in order to improve the engine’s anti-knocking performance. D The angle of the intake and exhaust is narrowed and set at 29_ to permit a compact cylinder head. D Spark plugs with an M12 thread size are used in order to increase the diameter of the intake and exhaust valves. As a result, improved intake and exhaust efficiency has been realized. D Upright intake ports are used to realize intake efficiency. D A taper squish combustion chamber is used to improve anti-knocking performance and intake efficiency. In addition, engine performance and fuel economy have been improved. D Long nozzle type fuel are installed in the cylinder head to reduce the distance from the fuel to intake valve, thus it prevents the fuel from adhering to the intake port walls, and reduces HC exhaust emissions. D The siamese type intake port is used to reduce the overall surface area of the intake port walls. This prevents the fuel from adhering onto the intake port walls, thus reducing HC exhaust emissions.

Camshaft Housing Intake A Valve Intake Side

Intake Spark Side Plug Exhaust Hole Side

Exhaust Side Upright Exhaust Intake Port Valve A Taper Squish View from Bottom Side A – A Cross Section

04FEG66Y 04FEG67Y

— REFERENCE —

Siamese Type Independent Type

215EG18 215EG19 EG-8 ENGINE – 2ZR-FE ENGINE

4. Cylinder Block D An aluminum cylinder block with a 7 mm (0.28 in.) distance between the cylinder bores is used to realize a compact and lightweight configuration. D An oil separator is provided in the blowby gas passage inside the cylinder block. This separates the engine oil from the blowby gas in order to reduce the degradation and consumption of volume of the engine oil. D It is not possible to bore the block with this liner. The liners are the spiny type, which have been manufactured so that their casting exterior form a large irregular surface in order to enhance the adhesion between the liners and the aluminum cylinder block. The enhanced adhesion helps heat dissipation, resulting in a lower overall temperature and reduced heat deformation of the cylinder bores. D Through the use of the offset , the bore center is shifted 8 mm (0.31 in.) towards the intake, in relation to the crankshaft center. Thus, the side force to cylinder wall is reduced when the maximum pressure is applied, which contributes to fuel economy. Cylinder Block

Liner

Irregularly shaped outer casting surface of liner

Oil Separator

Oil Separator Cover 04FEG51Y

Bore Center Maximum Maximum Pressure Pressure

Crankshaft Center

Crankshaft Center 04FEG52Y 082EG10Y

Offset Crankshaft Center Crankshaft ENGINE – 2ZR-FE ENGINE EG-9

5. Piston D The piston is made of aluminum alloy to be compact and lightweight. D The piston head portion is a taper squish shape and accomplishes fuel combustion efficiency. D Full floating type piston pins are used. D The groove of the top ring is applied with hard anodizing treatment to ensure abrasion resistance. D Low-tension piston rings are used to reduce friction and achieve excellent fuel economy. D Narrow-width piston rings are used to reduce weight and friction. D A No. 1 compression ring with an inside bevel shape is used to reduce blowby gas. D A PVD (Physical Vapor Deposition) coating has been applied to the surface of the No. 1 compression ring and oil ring, in order to improve its wear resistance. D The piston skirt is coated with resin to reduce the friction loss.

Taper Squish Shape PVD Coating No. 1 Compression Ring

No. 2 Compression Ring

Hard Anodizing Oil Ring Treatment Resin Coating PVD Coating

04FEG117Y 6. and Connecting Rod Bearing D The connecting rods are made of high-strength steel weight reduction. D Plastic region tightening bolts are used for a light design. D The connecting rod bearings have been optimized in width to reduce friction. D The lining surface of the connecting rod bearing has been micro-grooved to realize an optimal amount of oil clearance. As a result, cold-engine cranking performance has been improved and engine vibrations have been reduced.

Micro-grooved

Connecting Rod Bearing

04FEG68Y 04FEG200Y Plastic Region Tightening Bolts EG-10 ENGINE – 2ZR-FE ENGINE

7. Crankshaft and Crankshaft Bearing D The crankshaft has 5 journals and 8 balance weights. D The crankshaft bearings have been optimized in width to reduce friction. D The pins and journals have been machined with increased precision and the surface roughness is minimized to reduce friction. D The lining surface of the crankshaft bearing has been micro-grooved to realize an optimal amount of oil clearance. As a result, cold-engine cranking performance has been improved and engine vibrations have been reduced.

Oil Hole No. 5 Journal

Upper Oil Groove

08SEG38I No. 1 Journal Balance Weight

04FEG87Y Micro-grooved Lower Main Bearing 8. Oil Pan D The No. 1 oil pan ( case) is made of aluminum alloy. D The No. 2 oil pan is made of steel. D The oil pump is installed in the No. 1 oil pan to make the engine compact. D To improve serviceability, the No. 1 oil pan has been designed so that it can be removed without removing the No. 2 oil pan and the oil pump. D The air conditioning compressor brackets are integrated into the No. 1 oil pan.

No. 1 Oil Pan (Crank Case)

No. 2 Oil Pan

Oil Pump

04FEG71Y ENGINE – 2ZR-FE ENGINE EG-11

JVALVE MECHANISM

1. General D Intake and exhaust efficiency has been increased due to the larger total port areas. D The 2ZR-FE engine uses roller rocker arms with built-in needle bearings. This reduces the friction that occurs between the and the areas (roller rocker arms) that push the valves down, thus improving fuel economy. D The hydraulic lash adjusters, which maintain a constant zero valve clearance through the use of oil pressure and spring force, are used. D The intake and exhaust are driven by a timing chain. D The 2ZR-FE engine uses a Dual VVT-i (Variable Valve Timing-intelligent) system which controls the intake and exhaust camshafts to provide optimal valve timing according to driving conditions. With this, lower fuel consumption, higher engine performance, and fewer exhaust emissions have been achieved. For details of Dual VVT-i control, see page EG-49.

Exhaust Camshaft Intake Camshaft No. 2 Chain Damper Roller Rocker Arm Exhaust VVT-i Controller

Chain Exhaust Tensioner Valve Intake VVT-i Intake Hydraulic Lash Controller Valve Adjuster

Chain Damper Chain Slipper

Valve

04FEG72Y EG-12 ENGINE – 2ZR-FE ENGINE

2. Camshaft D The intake and exhaust camshafts are made of alloy. D An oil passage is provided in the intake and exhaust camshafts in order to supply engine oil to the VVT-i system. D A VVT-i controller has been installed on each front of the intake and exhaust camshafts to vary the timing of the intake and exhaust valves. D Together with the use of the roller rocker arm, the cam profile has been designed with an indented R (radius). This results in increased valve lift when the valve begins to open and finishes closing, helping to achieve enhanced output performance. D A timing rotor for the camshaft position sensor is provided at each back end of the intake and exhaust camshafts.

Exhaust VVT-i Timing Rotor Controller

Intake VVT-i Controller Indented R Portion of Cam (Profile)

Cam with Indented R 04FEG54Y 3. Timing Chain and Chain Tensioner D A roller chain with an 8 mm pitch is used to make the engine more compact. D The timing chain is lubricated by a timing chain oil jet. See page EG-13 for the location of the timing chain oil jet. D The chain tensioner uses a spring and oil pressure to maintain proper chain tension at all times. The chain tensioner suppresses noise generated by the timing chain. D The chain tensioner is ratchet type with a non-return mechanism. D To achieve excellent serviceability, the chain tensioner is constructed so that it can be removed and installed from the outside of the timing chain cover.

No. 2 Chain Damper Chain Tensioner

Chain Damper

Chain Slipper

04FEG168Y ENGINE – 2ZR-FE ENGINE EG-13

4. Hydraulic Lash Adjuster D The hydraulic lash adjuster, which is located at the fulcrum of the roller rocker arm, consists primarily of a plunger, plunger spring, check ball, and check ball spring. D The engine oil that is supplied by the cylinder head and the built-in spring actuates the hydraulic lash adjuster. The oil pressure and the spring force that act on the plunger push the roller rocker arm against the cam, in order to adjust the valve clearance that is created during the opening and closing of the valve. As a result, engine noise is reduced. Cam Plunger Hydraulic Roller Rocker Arm Lash Adjuster

Oil Check Ball Passage

Check Ball Spring

Plunger Spring 04FEG55Y

Service Tip Valve clearance adjustment is not necessary because a hydraulic lash adjuster is used.

5. Timing Chain Cover D An aluminum die-cast timing chain cover is used. D The timing chain cover has an integrated construction consisting of the cooling system (water pump and water passage). Thus, the number of parts has been reduced for weight reduction. D The oil passage is provided on the timing chain cover to simplify the oil passage. D The timing chain oil jet is provided in the timing chain cover. D A drive belt tension gauge is provided on the timing chain cover.

Timing Chain Cover Oil Passage

A Timing Chain Drive Belt Oil Jet Tension Gauge

Water Passage

Water Pump Gasket View from A

Water Pump 04FEG73Y EG-14 ENGINE – 2ZR-FE ENGINE

JLUBRICATION SYSTEM

1. General D The lubrication circuit is fully pressurized and oil passes through an . D The trochoid gear type oil pump is chain-driven by the crankshaft. D The 2ZR-FE engine has an oil return system in which the oil is force-fed to the upper cylinder head and returns to the oil pan through the oil return hole in the cylinder head. D The 2ZR-FE engine uses the Dual VVT-i system. This system is operated by the engine oil.

VVT-i Controller

Chain Tensioner

Oil Filter

04FEG113Y

" Oil Capacity A

Dry 4.7 Liters (5.0 US qts, 4.1 Imp. qts) With Oil Filter 4.2 Liters (4.4 US qts, 3.7 Imp. qts) Without Oil Filter 3.9 Liters (4.1 US qts, 3.4 Imp. qts)

" Oil Circuit A

Oil Passage (Timing Chain Cover) Main Oil Hole

Cylinder Head Timing Chain Piston Crankshaft Oil Jet Bypass Oil Filter Oil Jet Journal Intake Exhaust Oil Delivery Valve Camshaft Camshaft Pipe Timing Chain Journal Journal Piston Crank Relief Intake Exhaust Valve Oil Pump Pin Lash Chain Adjuster Camshaft Camshaft Tensioner Timing Oil Timing Oil Connecting Control Valve Control Valve Oil Strainer Rod Intake Exhaust VVT-i VVT-i Controller Controller

Oil Pan

04FEG79Y ENGINE – 2ZR-FE ENGINE EG-15

2. Piston Oil Jet D Piston oil jets for cooling and lubricating the have been provided in the cylinder block. D These oil jets contain a check ball to prevent oil from being fed when the oil pressure is low. This prevents the overall oil pressure in the engine from dropping.

Oil

Check Ball Oil Jet Cross Section

Piston Oil Jets

Bottom Side View 04FEG74Y EG-16 ENGINE – 2ZR-FE ENGINE

JCOOLING SYSTEM D The cooling system is a pressurized, forced-circulation system with simple-closing reserve tank. D A with a bypass valve is located in the water inlet housing to maintain a suitable temperature in the cooling system. D The flow of the engine coolant makes a U-turn in the cylinder block to ensure a smooth flow. In addition, a bypass passage is enclosed in the cylinder head and the cylinder block. D Warm water from the cylinder head is sent to the throttle body to prevent freeze-up. D The TOYOTA Genuine Super Long Life Coolant (SLLC) is used.

" Water Circuit A

From Heater Core

Water Pump

To Heater Core

To Radiator

From Radiator

04FEG80Y

Cylinder Head Heater Core

Cylinder Block

Water Pump

Reserve Thermostat Tank

Radiator Throttle Body 08SEG33Y ENGINE – 2ZR-FE ENGINE EG-17

" Specifications A

TOYOTA Genuine Super Long Life Coolant (SLLC) or similar high quality based non-silicate, non-amine, non-nitrite and non-borate coolant with long-life hybrid Type organic acid technology (coolant with long-life hybrid organic acid technology is a Engine combination of low phosphates and organic Coolant acids). Do not use plain water alone. Capacity 5.5 Liters (5.8 US qts, 4.8 Imp. qts) Color Pink First time 100,000 mile (160,000 km) Maintenance Intervals Subsequent Every 50,000 mile (80,000 km) Thermostat Opening Temperature _C (_F) 80 – 84 (176 – 183)

SLLC is pre-mixed (the U.S.A. models: 50% coolant and 50% deionized water, the Canada models: 55% coolant and 45% deionized water). Therefore, no dilution is needed when SLLC in the vehicle is added or replaced. EG-18 ENGINE – 2ZR-FE ENGINE

JINTAKE AND EXHAUST SYSTEM

1. General D The intake manifold has been made of plastic to reduce the weight and the amount of heat transferred from the cylinder head. As a result, it has become possible to reduce the intake air temperature and improve the intake . D A stainless steel exhaust manifold is used for weight reduction. D A throttle body mesh is used between the throttle body and the intake manifold to improve the flow of air within the intake manifold. D Two TWCs (Three-Way Catalytic converters) are used in the exhaust pipe.

" Intake Manifold A " Exhaust Manifold A

Air Cleaner

Exhaust Manifold

Intake Manifold

TWCs 08MEG01Y ENGINE – 2ZR-FE ENGINE EG-19

2. Air Cleaner D A nonwoven, full-fabric type air cleaner element is used. D A charcoal filter, which adsorbs the HC that accumulates in the intake system when the engine is stopped, is used in the air cleaner cap in order to reduce evaporative emissions.

Charcoal Filter Air Cleaner Cap

Air Cleaner Element (Nonwoven Fabric)

08SEG07Y

Service Tip The charcoal filter, which is maintenance-free, cannot be removed from the air cleaner cap.

3. Throttle Body D The linkless-type throttle body is used and it realizes excellent throttle control. D A DC motor with excellent response and minimal power consumption is used for the throttle control motor. The ECM performs the duty cycle control of the direction and the amperage of the current that flows to the throttle control motor in order to regulate the opening angle of the throttle valve.

Throttle Position Sensor

Throttle Control Motor 04FEG77Y EG-20 ENGINE – 2ZR-FE ENGINE

4. Exhaust Pipe D 2 ball joints are used to joint the exhaust manifold to the front pipe, and the front pipe to the tailpipe. As a result, a simple construction and improved reliability have been realized. D The TWC can improve exhaust emission by optimizing the cell density and the wall thickness.

with Diffuser Models Gasket

Tailpipe

Spring Ball Joint

Main

Sub Muffler Ball Joint Portion Ball Joint Portion

Front Pipe

TWCs 08MEG02Y