Toyota Kluger workshop repair manual

The Toyota Highlander, also called the Toyota Kluger, was a midsize crossover SUV made by Toyota. Revealed in April 2000 at the ny car tv show and arriving in belated 2000 in Japan and January, 2001, in united states, the Highlander

Toyota Highlander Kluger Lexus RX300 RX330 Harrier 1999-2014

car repair service maintenance manual book
Toyota Kluger Haynes repair manual 1999 -2007 Get other Toyota repair manuals here Haynes (USA) publication No.92095 covering Toyota Highlander (Kluger) Lexus RX300/330 1999 thru 2014 (Softcover 304 pages).Haynes (USA) - American publication based on left-hand drive (LHD) versionsToyota Highlander from 2001 (second generation sold in Australia as the Kluger from October 2003)Lexus RX 300 from 1999 (not sold in Australia aka Toyota Harrier in Japan)Lexus RX 330 from 2003 (sold in Australia from April 2003 aka Toyota Harrier) Engines: 2.4 litre (2362 cc) 2AZ-FE DOHC 4 cylinder petrol. 3.0 litre (2994 cc) 1MZ-FE DOHC V6 petrol.3.3 litre (3311 cc) 3MZ-FE DOHC V6 petrol.Table of contents: Introduction Chapter 1: Tune-up and routine maintenance Chapter 2: Part A: Four-cylinder engine Chapter 2: Part B: V6 engines Chapter 2: Part C: General engine overhaul procedures Chapter 3: Cooling heating and air conditioning systems Chapter 4: Fuel and exhaust systems Chapter 5: Engine electrical systems Chapter 6: Emissions and engine control systems Chapter 7: Automatic transaxle Chapter 8: Driveline Chapter 9: Brakes Chapter 10: Suspension and steering systems Chapter 11: Body Chapter

Toyota Kluger 2003-2014 Workshop manual

car repair service maintenance manual book
Toyota Kluger V6 Petrol 2003 - 2014 Gregorys Owners Service Repair Manual covers: Series MCU28R GSU40R GSU45RPetrol Engines Covered: 3.3 litre V6 - 3MZ-FE 3.5 litre V6 - 2GR-FEContents: Tune-up and routine maintenance 3.3 litre V6 (3MZ-FE) Engine 3.5 litre V6 (2GR-FE) Engine General engine overhaul procedures Cooling heating and air conditioning systems Fuel and exhaust systems Engine electrical systems Emissions and engine control systems Automatic transaxle and transfer case Driveline Brakes Suspension and steering systems Body Chassis electrical system Wiring DiagramsNOTE: Only maintenance adjustment minor repair procedures plus removal and installation are described for the Transmissions.

The Toyota Highlander, also called the Toyota Kluger, was a midsize crossover SUV made by Toyota. It is constructed on the platform of Toyota Camry.

Revealed in April 2000 at the ny car tv show and arriving in belated 2000 in Japan and January, 2001, in united states, the Highlander became among the first car-based midsize SUV or midsize crossovers. The Highlander is the crossover equivalent towards the more durable, truck-based midsize 4Runner and became Toyota's best-selling SUV before being exceeded by the small RAV4 in 2006. In Japan, the Kluger try exclusive to dealership network known as Toyota NETZ as a more substantial substitute for the RAV4.

Not able to use the Highlander title in Japan and Australia as a result of a trademarked Hyundai Terracan trim range, Toyota calls the vehicle the Toyota Kluger there, title derived from the German term klüger, which means that clever or sensible.

The Highlander shared a system along with its Lexus RX/Toyota Harrier cousin. They came in five and seven-seat configurations and became a sales profits for Toyota in many different areas across the world. The Highlander came traditional with front-wheel drive and provided all wheel drive. Unlike Toyota's own 4Runner as well as other mid-sized competitors such as the Jeep Grand Cherokee, or Chevrolet TrailBlazer, the Highlander aimed for on-road comfort having its device body construction and separate back suspension system. Though it is longer than the 1996–2002 4Runner offered at enough time it was launched, the Highlander ended up being surpassed long because of the redesigned 4Runner in 2002.

The Highlander is available in three trim outlines in the usa: the base model, the activity model, as well as the restricted design. The bottom and restricted designs were current if the Highlander was initially launched, as the recreation model had been launched in March 2006. In Japan, it is considered to be an extra car since the Kluger surpasses Japanese Government laws managing engine displacement and outside dimensions.

In 2004 the tires on the restricted trim changed from a six-spoke, to a five-spoke alloy. The base-model Highlander rims furthermore altered from steel-rims to your alloy wheels that were regarding 2001–2003 design season Highlander restricted and B-Package. The game brands have a distinctive grille design, distinguishing by themselves from non-Sport brands. Wheel styling furthermore serves to separate the many models—the crossbreed activities a unique twin-spoke build.

The Kluger ended up being introduced to Australia during 2003. It was obtainable in three guises: CV, CVX, and Grande. A restricted version CV athletics model was also revealed in 2006. There clearly was no crossbreed design available in Australian Continent. The actual only real system supplied was the 3.3-liter 3MZ-FE V6.


2001–2007 2.4 L 2AZ-FE I4, 155 hp
2001–2003 3.0 L 1MZ-FE V6, 220 hp
2004–2007 3.3 L 3MZ-FE V6, 225 hp

The 3.0-liter engine surely could propel the Kluger from 0–60 miles per hour in around 8.8 moments. In 2004 the Kluger was presented with a new 3.3-liter V6 system to take on the greater amount of effective V6 choices from the competition, mainly the Nissan Murano while the Honda Pilot. The larger engine caused it to be possible for the Kluger to attain 0 to 60 miles per hour in 7.8 seconds.

The Toyota AZ system family try a straight-4 piston system show. The AZ show makes use of an aluminum motor block with cast iron cylinder liners and aluminum DOHC cylinder heads. The system series features numerous advanced level technology including slant-squish burning chambers, offset cylinder and crank centers, additionally the VVT-i continually variable intake valve time program. The aluminium motor steps 626 mm long, 608 mm wide, and 681 mm tall.

The cylinder block is an open-deck, midi-skirt die-cast aluminium means with cast-in metal liners and a die-cast aluminum lower crankcase and a stamped oil cooking pan. The forged steel crankshaft is fully balanced with eight counterweights and sustained by five primary bearings. A helical gear pushed in No. 3 counterweight drives twin contra-rotating stability shafts into the shaft housing inside the reduced crankcase.

The twin expense camshafts become driven by a single-stage roller chain of 8.0 mm pitch, enabling a slim included valve angle of 27.5°. The camshafts act on four valves per cylinder via bucket tappets. As with the recent Toyota system training, no approval adjusting shim is utilized. Device diameters are 34.0 mm for consumption and 29.5 mm for exhaust, with 8.0 mm raise both for intake and exhaust. The four-vane VVT-i unit is equipped on intake camshaft, changing timing by 50°. The valve address is constructed of magnesium to save lots of fat.

Fuel try injected sequentially via an ultra-fine-atomization injector with twelve tiny shot holes, each 0.18 mm in diameter. Such as the smaller NZ engine, the newest AZ adopts a plastic, built-up, and vibration-welded intake manifold integrating a sizable amount plenum chamber volume like a 1.3 L resonator). Fatigue manifolds is of tubular building with incorporated catalytic converters.

The AZ may be the alternative to the S motor. It will eventually be replaced because of the AR system.

Toyota disclosed the second-generation Highlander and Highlander Hybrid at 2007 Chicago car Show, with US product sales from July and hybrids in belated September. Nevertheless second-generation Highlander and Highlander crossbreed are not sold in Japan. The five-seat Highlander for united states of america and Canada was dropped while the bigger Venza replaced it.

In the beginning the sole powertrain when it comes to 2008 Highlander ended up being a 270 horse power 3.5-liter 2GR-FE V6 mated to a five-speed automatic. The four-cylinder model had been discontinued but included once more during 2009. Even though the 3.5-liter engine have 55 even more bhp compared to the past 3.3-liter V6 and dimensional increases with enhanced sound proofing included almost 500 lbs into the automobile's curb fat of approximately 4,000 pounds, gasoline economic climate try a little improved. The EPA expected gasoline economy for front-wheel drive models has reached 18 mpg-US city / 24 mpg-US highway city / 23 mpg-US hwy).

For 2009, Toyota again supplied a 4-cylinder for 5-passenger front-wheel drive models aided by the all-new ULEV-II certified 2.7-liter 1AR-FE I4 paired to a six-speed automated. It makes 187 hp at 5,800 rpm and 186 lb·ft of top torque at 4,100 rpm on regular 87 octane gasoline. The four-cylinder brings an EPA calculated gasoline economy of 20 mpg-US city and 27 mpg-US highway. That is a lot better than the last design's four-cylinder with 19 mpg-US/25 mpg-US.

Similar three trim values are provided until early 2010 as soon as the SE model replaced the activity design, purchasers continue to be able to choose from front-drive or all-wheel drive on V6 platforms. Furthermore new is a power energy Steering system. Sport and brief products get a standard back up digital camera utilizing a 3.5-inch Liquid Crystal Display screen. Biggest choices incorporate fabric chairs, heated seating, a touch-screen DVD formulated navigation program, a new practical Key System, an upgraded JBL Synthesis stereo, a rear-seat DVD entertainment system with 9-inch display screen, and a towing bundle that grows pulling capacity to 5000 pounds.

The XU40 was initially produced exclusively in Japan for many global areas beginning in May 2007. LHD production occurred on Miyata plant in Miyawaka, Fukuoka, with Daihatsu's Ikeda plant in Ikeda, Osaka making for RHD areas. Manufacturing in Asia for regional marketing is began on 25 May 2009 by GAC Toyota in Nansha District, Guangzhou, Guangdong. Toyota had meant on design the Highlander in azure Springs, Mississippi for the united states marketplace inside 2011 model seasons. But the Corolla ended up being built here rather, therefore the Highlander has been built at Toyota Motor Manufacturing Indiana in Princeton, Indiana, from the 2010 model season forward for a lot of the united states, changing Tundra production. TMMI Highlander production began in October 2009 for fuel system models only; hybrids always been imported from Japan before the launch of the 3rd generation XU50, in which all manufacturing except for Asia is consolidated at TMMI.

In Australian Continent, the brand new generation Kluger was launched in August, 2007. There are three grades readily available, KX-R, KX-S and Grande. All grades are available with either 2WD or AWD. The base model KX-R can be offered with either five or seven seats, as the second grades were seven seaters best. Standards are mostly much like the US Highlander, sharing the exact same 3.5-litre V6 2GR-FE motor and five-speed automated transmission. But there are no projects at the moment to introduce a hybrid form of the Kluger to the Australian marketplace.

Energy assisted steering or motor-driven power steering makes use of an electrical engine to aid the driver of an automobile. Detectors detect the position and torque for the steering line, and a pc component applies assistive torque via the engine, which links to either the steering gear or steering column. This permits different amounts of assist with be used based on operating problems. Designers can therefore modify steering-gear response to variable-rate and variable-damping suspension system methods, optimizing ride, managing, and steering for each vehicle. On Fiat team automobiles the quantity of aid are controlled utilizing a button named "CITY" that switches between two various support curves, while most other EPS systems need variable help. These promote even more help since the vehicle decelerates, and less at faster speeds.

a mechanical linkage involving the steering wheel in addition to steering gear are retained in EPAS. In case of component failure or energy troubles that creates failing to offer support, the technical linkage functions as a back-up. When EPAS fails, the motorist encounters a situation where hefty efforts is required to guide. This heavy energy is comparable to compared to an inoperative hydraulic steering support system. With respect to the travel scenario, operating experience and power of the driver, steering assist reduction may or may not trigger a collision. The difficulty of steering with inoperative power steering are compounded because of the selection of steering ratios in assisted steering gears vs. totally handbook. NHTSA has actually assisted automobile manufacturers, such as Ford, with remembering EPAS techniques prone to failure.

Electric methods posses a plus in fuel efficiency since there is no belt-driven hydraulic pump continuously run, whether assistance is required or otherwise not, and this is a significant reason for their introduction. Another major benefit may be the eradication of a belt-driven system accessory, and many high-pressure hydraulic hoses between the hydraulic pump, installed on the system, together with steering gear, attached to the chassis. This significantly simplifies production and repair. By incorporating electric security controls electric power steering methods can instantly differ torque assist levels to assist the motorist in corrective maneuvers.

The initial energy steering program made an appearance regarding the Suzuki Cervo in 1988. The device has-been applied by numerous car makers.

For the 2011 model season, Toyota made some changes towards Highlander and Highlander crossbreed. Whilst general build continues to be just like the 2010 model, the Highlander's forward end happens to be notably modified, now featuring new headlights, a brand new black with chrome accent rocker panel, and new-front grille. The non-hybrid machines for 2011 stays similar, although today the 2.7-liter four-cylinder engine can be have from the SE trim degree, earlier just available on the beds base design. Most standard properties are now actually equipped on all trim level, with the base model obtaining front side and rear ac, energy locks/windows, cruise controls, and a multi-function keyless entry controls.
NHTSA crash test score: Frontal Driver: 5/5 stars
Frontal Traveler: 4/5 movie stars
Side Driver: 5/5 movie stars
Side Rear Traveler: 5/5 movie stars
Rollover: 4/5 movie stars

All models come standard with improved Vehicle Stability controls which straight away alters electric powering steering assist w/traction control, anti-lock brake system, brake assist and digital brakeforce circulation. In addition standard try a tire force monitor, a driver's leg airbag, front seat-mounted part torso airbags, side curtain airbags for many three rows which includes a rollover sensor and energetic front side headrests. Hill Start support Control normally standard which stops moving backwards on mountains, and Downhill aid controls was standard on AWD trims.

The IIHS costs the Highlander "close" general in their frontal offset crash test, and close in most subcategories excluding "Head/neck," that is rated as "Acceptable." And "Good" total into the side impact crash test, with "close" rating in all nine assessed groups. The Highlander can be rated "close" into the roof power test, offering they a high Safety choose award.

In Australasian brand new automobile Assessment plan testing the Kluger was considering a 5/5 movie stars rating but just a 1/4 movie stars score for pedestrian coverage.

The security and effectiveness of Highlander/Kluger's car security controls system is questioned by some motoring journalists. During examination for tires mag vehicle of the Year in 2007, the magazine's editor rolled the vehicle during high-speed gravel road-testing. Noting that it was the initial such event in the mag's 45-year records, he criticised the car's stability system stating that "too little the Kluger's ESP contributed to your crash". Six of seven other judges furthermore claimed that they experienced "the vehicle's ESP overall performance had been sub-standard", and remarked the automobile ended up being "almost dangerous on soil ". In a written responses, Toyota disputed the situations associated with the accident and criticised the assessment processes as "unscientific".

On March 27, 2013, Toyota unveiled the third-generation XU50 show Highlander during the nyc Overseas automobile tv show, with intends to possess vehicle go dealerships at the beginning of 2014. Production started on December 5. This version was longer and broader compared to the outgoing generation and its design has changed from the boxy turn to one that is comparable to various other mid-size crossover SUVs.

In addition to the changes, that one will showcase sitting for eight people who have a sliding second-row point of entry that provides it 4.3 inches of added circumference space, soft-touch items regarding the instrument panel, lane-departure caution, pre-collision caution and blind place monitoring techniques. HD Radio and Bluetooth will end up a standard on all trims when it comes to US variation, that may in addition come built with Toyota's Entune media program and a 6.1-inch touchscreen screen audio system. An eight-inch touchscreen program and Toyota's Entune application package with 12 JBL speakers is supposed to be offered as an optional feature. The three powertrain trims which will be supplied include a 2.7L/6-speed front-wheel drive base model, a 3.5L/6-speed 6AT design in both front-wheel or all wheel drive, while the AWD-only crossbreed trim with a 3.5L/V6 mated to an eCVT.

The latest Highlander can be authorized for usage as a New York City taxicab.
The anti-lock brake operator can also be referred to as CAB.

Typically ABS include a central digital controls unit, four wheel speeds detectors, as well as the very least two hydraulic valves in the braking system hydraulics. The ECU constantly tracks the rotational speed of each wheel; if it detects a wheel turning dramatically slower than the other individuals, a condition indicative of impending wheel lock, they actuates the valves to lessen hydraulic stress to the brake within affected wheel, thus decreasing the stopping force on that wheel; the wheel after that turns quicker. Conversely, if the ECU detects a wheel switching dramatically faster as compared to other individuals, brake hydraulic stress toward wheel try enhanced and so the braking force is reapplied, slowing the wheel. This method is repeated constantly and that can be detected by the motorist via brake pedal pulsation. Some anti-lock methods can put on or discharge braking stress 15 occasions per 2nd. As a result of this, the tires of cars built with ABS tend to be almost impractical to lock even during panic braking in severe circumstances.

The ECU was set to disregard variations in wheel rotative rate below a crucial limit, since when the automobile was switching, the 2 tires towards the center for the curve switch slower as compared to outer two. With this same factor, a differential can be used in virtually all roadgoing automobiles.

If a fault develops in almost any an element of the ABS, a warning light will usually become illuminated regarding vehicle instrument panel, additionally the ABS should be disabled until the fault is rectified.

Todays ABS applies specific braking system force to all the four rims through a control program of hub-mounted detectors and a passionate micro-controller. abdominal muscles is offered or appear standard on most road motors produced today and it is the inspiration for electric security control techniques, that are rapidly increasing in popularity as a result of the big lowering of cost of vehicle electronics through the years.

Modern-day electronic security control methods is a development associated with the abdominal muscles idea. Right here, no less than two extra detectors are put into assist the system work: they are a steering wheel position sensor, and a gyroscopic sensor. The theory of operation is easy: once the gyroscopic sensor detects that direction taken because of the automobile cannot coincide as to what the steering wheel sensor reports, the ESC pc software will brake the required individual wheel, so that the automobile goes what sort of driver intends. The steering wheel sensor also helps in the procedure of Cornering Brake Control, since this will inform the abdominal muscles that wheels inside the bend should brake more than tires on the outside, by exactly how much.

ABS equipment doubles to implement a grip controls program on acceleration associated with the automobile. If, when accelerating, the tire manages to lose grip, the ABS operator can detect the specific situation and need suitable activity making sure that grip was regained. Much more sophisticated models of the may manage throttle amount and brake system at the same time.

The speed sensors of abdominal muscles are occasionally found in indirect tire stress monitoring system, that may detect under-inflation of tire by difference between rotational speed of wheels.

You can find four main the different parts of ABS: wheel speed sensors, valves, a pump, and a controller.

Speed detectors
a speed sensor can be used to determine the acceleration or deceleration of the wheel. These detectors make use of a magnet and a Hall influence sensor, or a toothed wheel and an electromagnetic coil to create a signal. The rotation of this wheel or differential causes a magnetic industry round the sensor. The fluctuations of the magnetic field create a voltage in sensor. Since the voltage caused inside sensor is caused by the turning wheel, this sensor becomes incorrect at slow rates. The slow rotation of wheel could cause inaccurate fluctuations inside magnetized area and therefore result inaccurate readings toward controller.
There is a device in the brake line of each braking system influenced by the ABS. On some methods, the device has three jobs:

Constantly in place one, the device are available; stress through the master cylinder try passed away through toward brake.
In place two, the valve obstructs the range, isolating that braking system from master cylinder. This prevents pressure from increasing further if the driver press the braking system pedal harder.
Constantly in place three, the valve releases a few of the pressure from brake.

Many issues with the device system happen due to blocked valves. When a valve try blocked it is incapable of start, near, or change place. An inoperable device will avoid the program from modulating the valves and controlling force provided toward brakes.

The pump within the ABS can be used to restore pressure to the hydraulic brake system after the valves posses introduced it. An indication from the controller will release the valve at recognition of wheel slip. After a valve launch the stress provided through the consumer, the pump is used to displace a desired number of force to your braking system. The controller will modulate the pumps status to supply the ideal quantity of stress and reduce slipping.
The operator try an ECU kind device when you look at the vehicles which obtains ideas from each individual wheel speed sensor, subsequently if a wheel loses traction the signal are provided for the controller, the controller will likely then limit the braking system energy and activate the ABS modulator which actuates the braking valves off and on.