The 2ZZ-GE Engine from Toyota - Yamaha with the MMC Cylinder Coating

Here, I gathered all information I have found about the famous 2ZZ-GE Engine from Toyota - Yamaha:

The 2ZZ-GE engine, a 1.8 Liter in-line 4 cylinder, was developed and introduced to the market for the 2000 model year Celica sports car. The engine was based on the 1.8 Liter 1ZZ-FE (1) which has a longer piston stroke and cast iron cylinder liners. The specifications of the 1ZZ-FE and 2ZZ-GE engines are shown in Table 1.

The RPM cuttoff is at 8200 to 8500 RPM depending on the model.

This engine is unique because of its MMC Cylinder Coating. It is an all aluminum cylinder block with a Metal Matrix Composite (MMC) cylinder bore that is composed of:

A casting technology to produce an almost defect free MMC block was established by adopting a laminar-flow die-cast filing and by developing control techniques for mold temperature, squeeze pin and gas discharge.

Cylinder Head

Along with the adoption of the VVTL-i (Variable Valve Timing and Lift-intelligent) system, the cylinder head supports the installation of the rocker arm, rocker shaft, and oil control valve housing.

Upright intake ports are used to increase intake efficiency.

The injectors have been installed in the cylinder head to prevent the fuel from adhering onto the intake port walls, thus reducing exhaust emissions.

A water bypass passage has been provided below the intake ports to reduce the number of parts and to reduce weight.

The 2ZZ-GE is a high speed motor (8200-8500 rpm) with Flat Tappets (the red ones in the drawing) for the high speed LIFT mechanism. Up to about 6200 rpm the low-mid cams are used which touch on needle roller bearings, but then the Flat Rocker Arm Pad locks and the high-speed cams are used which are pressing on flat tappets to push the valves down. 

[My suggestion from what I have read:] Therefore, an oil with higher viscosity (HTHS) and higher ZDDP content is required for engine longevity. [See here]

Cylinder Block

The crankshaft bearing caps with ladder-frame construction have been adopted to increase the rigidity, to reduce noise, and to increase the coupling rigidity with the transaxle.

Cast-iron is adopted as a material for part of the bearing journal of crankshaft bearing cap and thus help prevent heat deformation. In addition, the oil filter bracket, the air conditioner compressor bracket, the water pump swirl chamber, the thermostat housing and the rear oil seal retainer have been integrated to reduce the number of parts.

Oil jets are provided to ensure reliable cooling and lubrication of the pistons.

Piston

The piston is made of aluminum alloy to be compact and lightweight.

The piston surface is coated with iron and tin to reduce the sliding resistance friction between the piston and the cylinder wall.

Full floating type piston pins are used.

By increasing the machining precision of the cylinder bore diameter, only one size of piston is available.

Connecting Rod

The connecting rods are made of high-strength vanadium steel for weight reduction.

The connecting rod bearings have been reduced in width to reduce friction.

Nutless-type plastic region tightening bolts are adopted for a lighter design.

Crankshaft

The forged crankshaft has 5 journals and 8 balance weights.

The crankshaft bearings have been reduced in width to reduce friction.

The pins and journals have been machined with increased precision and the surface roughness minimized to reduce friction.

All info was taken from the following papers:

Development of Metal Matrix Composite for Cylinder Block

2ZZ-GE Engine

2ZZ-GE MMC All Aluminum Cylinder Block

Γωνία Τοποθέτησης Πίσω Αμορτισέρ Toyota Celica 7ης

Επειδή ήθελα να αλλάξω τα ελατήρια των πίσω αμορτισέρ (έβαλα τα original αντί των κοντών TEIN) διάβασα στο service manual τη διαδικασία εγκατάστασης των ελατηρίων-αμορτισέρ και διαπίστωσα ότι το σχέδιο που δίνει η Toyota για υπολογισμό της γωνίας - μεταξύ της Πάνω Βάσης Αμορτισέρ με την Κάτω Βάση Αμορτισέρ - δεν είναι πρακτικό. Συγκεκριμένα δείχνει το εξής σχέδιο:

Η γωνία 42,6 μοίρες, που δείχνει, δεν μπορεί να μετρηθεί εύκολα. Για αυτό έφτιαξα στο AutoCAD ένα σχέδιο που δείχνει τη γωνία της βίδας της κάτω βάσης του αμορτισέρ, σε σχέση με την πάνω βάση, η οποία πιστεύω ότι είναι πολύ πρακτικότερη.  Μπορείτε να εκτυπώσετε τα σχέδια σε Α3 σελίδα, να τα κολλήσετε σε χαρτόνι και στη συνέχεια στο πάτωμα. Πάνω θα βάλετε το αμορτισέρ με το συμπιεσμένο ελατήριο (δείτε στο τέλος ένα εργαλείο, ίδιο με αυτό που συνιστά η Toyota, για συμπίεση των ελατηρίων, που ταιριάζει σε πάρα πολλά αυτοκίνητα). Στην κάτω βάση του αμορτισέρ μπορείτε να βάλετε αντί της βίδας μια μακριά ντίζα ίδιας διαμέτρου, για να βλέπετε καλύτερα τη γωνία. Τα δικά μου σχέδια:

Δεξί: Γωνία Άξονα Βίδας Κάτω Βάσης Αμορτισέρ με Πάνω Βάση = 18,2 μοίρες

Αριστερό: Γωνία Άξονα Βίδας Κάτω Βάσης Αμορτισέρ με Πάνω Βάση = 18,2 μοίρες

Η σωστή γωνία κάτω βάσης με την πάνω βάση παίζει μεγάλο ρόλο, γιατί πρώτον αν γίνει λάθος δεν μπαίνει και δεύτερον γιατί αν έχετε μικρή διαφορά, αλλά παρόλα αυτά καταφέρετε να το τοποθετήσετε, μπορεί να αλλάξετε τη γεωμετρία της ανάρτησης ή να φορτίσετε το ελατήριο με δυνάμεις όχι μόνο συμπίεσης αλλά και περιστροφής.

Το εργαλείο συμπίεσης ελατηρίων:

                             Kraft & Dele Σετ Εξωλκείς για Ελατήρια Αμορτισέρ

Το οποίο είναι πολύ βολικό, γιατί έχει μόνο μια ντίζα που βιδώνεις για τη συμπίεση του ελατηρίου:

Προσοχή: Η διαδικασία αλλαγής ελατηρίων-αμορτισέρ είναι μόνο για έμπειρους τεχνικούς με τα κατάλληλα εργαλεία. Εσείς αναλαμβάνετε την ευθύνη των πράξεών σας αν κάτι πάει στραβά. Εγώ απλώς προσφέρω ένα βοήθημα πάνω στη διαδικασία που περιγράφεται αναλυτικά στο Service Manual της Toyota.

Toyota C Series Gearboxes for the Celica 7th (1999-06)

Toyota C Series Gearboxes for the Celica 7^th (1999-06)

This article is about the various Toyota C series Gearboxes that are used in the Toyota Celica 1999-2006 models.

Four gearboxes were used: 

C56 5 speed

C60 6 speed

C63 6 speed

C64 6 speed 

You can see the comparison of them in the last table but first I will describe them:

C56

The C56 is a 5-speed gearbox that was mainly used together with the Toyota 1ZZ-FE engine in the US.

Applications:

Toyota Celica GT

Toyota Corolla

Toyota Starlet Glanza V

Toyota Corolla Levin AE101 / Toyota Sprinter Trueno AE101 - later years

Toyota Corolla Levin AE111 / Toyota Sprinter Trueno AE111

Toyota MR2 Spyder (US/Japan) (mid-engine application)

Toyota Vios turbo

Toyota Vitz

Geo Prizm GSi (1990–1992)

Elise S (2007-2010)

Differential Options:

C56-01A: Open Differential

C56-01B: Torsen Limited Slip Differential (LSD)

C56-03A: Open Differential

C56-04C: Limited Slip Differential (LSD)

Gear ratios for this transmission:

1st	2nd	3rd	4th	5th	6th	Reverse	Final
3.166	1.904	1.392	1.031	0.815	-	3.250	4.312

 

C60

The C60 is a 6-speed gearbox that was mainly used with the Toyota 2ZZ-FE engine in the US.

Applications:

Toyota Celica GTS / T-Sport, 1999–2005 (US/Europe)

Toyota Corolla XRS 2005–2006

Toyota Matrix XRS 2003–2006

Pontiac Vibe GT 2003–2006

Lotus Elyse with the 2ZZ-FE?

Differential Options:

C60-02A: Without Limited Slip Differential (LSD)

C60-02B: With Limited Slip Differential (LSD)

Gear ratios for this transmission:

1st	2nd	3rd	4th	5th	6th	Reverse	Final
3.166	2.050	1.481	1.166	0.916	0.725	3.250	4.529

C63

The C63 is a 6-speed gearbox that was mainly used with the Toyota 1ZZ-FE engine in Europe.

Applications:

Toyota Celica ZZT230 with the 1ZZ-FE engine 1999-2005 (UK, Europe)

Gear ratios for this transmission.

1st	2nd	3rd	4th	5th	6th	Reverse	Final
3.166	1.904	1.310	1.031	0.864	0.725	3.250	4.312

C64

The C64 is a 6-speed gearbox that was mainly used together with the Toyota 2ZZ-FE engine in Europe. The main (and only?) difference with the C60 gearbox is its shorter 6th gear ratio (0.815) compared with the one of the C60 (0.725). The 6th gear of the C64 has higher rpm in the highway but has better torque than the 6^th gear of the C60. The 6th gear parts of the C64 and C60 are interchangeable, so you can install the 6th gear ratio that you desire. Because of this there are many used C60 C64 gearboxes that have a different 6^th gear ratio than their original, adding more confusion to the prospect buyers.

Applications:

Toyota Celica T Sport (UK)

Toyota Corolla Sportivo (Australia)

Toyota Corolla T Sport (UK/Europe)

Toyota Corolla T Sport Compressor (UK/Europe)

Toyota Corolla Fielder Z Aero Tourer (Japan)

Toyota Corolla Runx Z Aero Tourer (Japan)

Lotus Elise (manual mid-engine application)(US/UK/Europe), 2004–present

Lotus Exige (manual mid-engine application)(US/UK/Europe), 2005–present

Differential Options:

C64-01A: Open Differential

C64-01B: With Limited Slip Differential (LSD)

Gear ratios for this transmission.

1st	2nd	3rd	4th	5th	6th	Reverse	Final
3.166	2.050	1.481	1.166	0.916	0.815	3.250	4.529

Synchros of C56, C60, C64

“...There was a design change to the 3rd and 4th gear synchros in 2003/2004. Your 3rd and 4th gears, synchro rings and 3rd-4th hub ring must all be either early or late. If you have an early transmission then during a rebuild you can upgrade to the late style synchros which are a bit better in durability and performance…”

More information in the following article from Monkey Wrench Racing:

https://www.monkeywrenchracing.com/transmissions-lotus-toyota-c60-and-c-series/

I have made an Excel file that I use to calculate the final traveling speed (in km/h) for every gear and the rpm for various traveling speeds, by using the engine cut off speed (in rpm) and the tire dimensions. I am trying to make an automatic form that you can use for your specific tire dimensions and engine cut off speed but at the moment is not working, so I am posting pdf files for the most common tire dimensions (205/50/16 and 215/45/17) and 8200 rpm engine cut off speed:
205/50/16 - 8200 rpm
215/45/17 - 8200 rpm

All information was gathered by the following
websites:
https://en.wikipedia.org/wiki/Draft:Toyota_C_transmission
https://www.mygarageiscoolerthanyours.com/information/c-series-ratios
https://midshiprunabout.org/mk3/gear-ratios/
https://wiki.seloc.org/a/Toyota_Gearboxes

This would be the form when I fix the html code (it is now not working):

Tire Width:
Tire Height:
Wheel Diameter:
Shift RPM:


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