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The 2ZZ-GE is a sporty 1.8 liter engine based on the 1ZZ-FE, which is currently being mass produced in Japan, USA, and Canada. It was designed to fit into the same engine compartment as the base 1ZZ-FE, have equivalent vehicle performance as a 2.2 liter engine, and meet TLEV emission standards. The main features of the 2ZZ-GE are the Metal Matrix Composite (MMC) reinforced all-aluminum cylinder block and the intelligent Variable Valve Timing and Lift (VVTL-i) system. These features were adopted for size and performance. Other features such as a reinforced ladder frame, and an intake manifold spacer was utilized for a sporty engine sound. The 2ZZ-GE delivers maximum power at 7600rpm and maximum torque at 6800rpm.

The synchronous belt employed in the valve train of automotive engines is operated under fluctuating load. Two types of the belt vibration are observed. One is the well-known lateral vibration. The other is the vibration in the belt running direction which may cause the resonant vibration of the camshaft rotation and may affect the belt life. The purpose of this paper is to describe an analysis of the latter vibration. This vibration was analyzed using the model composed of the inertia moment of the camshaft system and the nonlinear elasticity of the belt in the running direction. The predicted resonant frequency and amplitude were in good agreement with the measured ones. The influence of each factor of the model on the vibration was also investigated. The stiffness in the belt running direction that is determined by the tooth distortion When the belt engages with the pUlley should be increased to reduce the amplitudes of the resonant Vibration.

Lubrication of a connecting rod bearing is analyzed by the theory of elastohydrodynamic lubrication (EHL). The hydrodynamic of a connecting rod bearing was calculated in consideration of not only the effects of bearing elastic deformation but also those of bearing shapes. Journal center loci were measured to confirm the accuracy of calculated results. The governing equations of EHL are the Reynolds equation, the clearance gap equaution and the load equation. The effects of the shapes of a connecting rod bearing were included in the clearance gap equaution. The calculated results agree well with the measured results. Results of this study show that lubrication of a connecting rod journal bearing is significantly influenced by bearing elastic deformation and shapes of a connecting rod bearing.

Computer Aided Engineering System for crankshaft damper pulley design was developed. This system enables a designer to develop a high performance crankshaft damper pulley in a short time. This system consists of computer simulation for torsional vibration of crankshaft with a damper pulley and parametric damper pulley design program. High accuracy and easy operation are required for the simulation. New procedure of FE analysis which can accurately and easily predict stiffness of crankshaft in less than 4 hours was developed. And the database for damper rubber property which was measured under the condition of wide range enough to cover actual engine operation was created. It was shown that the calculated results agree well with the experimental results. Parametric damper pulley design program were developed. This program is composed of the design standards and stores of know-how in Toyota.

Computer Aided Engineering system for automotive piston design was developed which can predict total piston performance in a short time at the planning stage of piston design. Many previous studies attempted to calculate piston performance accurately with experimental data and their main purpose was not to create a tool for piston design. The purpose of this CAE system is to provide a tool for a designer to predict total piston performance easily and rapidly without experimental data. This system has following two characteristics. Firstly, new finite element methods were developed which can predict temperature distribution without experimental data, thermal skirt expansion for a strutted piston and skirt-to-bore contact pressure under engine operating conditions. The predicted result are accurate enough to predict piston performance at the planning stage of piston design.