Toyota Kluger workshop repair printed manual Workshop Manuals

Toyota Kluger workshop repair printed manual

The Toyota Highlander, also called the Toyota Kluger, is a midsize crossover SUV created by Toyota. Announced in April 2000 on nyc automobile Show and showing up in late 2000 in Japan and January, 2001, in the united states, the Highlander

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2GR-FE Contents: * Tune-up and routine maintenance * 3.3 liter Vee Six (3MZ-FE) Engine * 3.5 liter Vee Six (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 * braking system * Suspension and Rack and pinion systems * Body * Chassis electrical system * electrical schematics NOTE: Only maintenance adjustment simple maintenance tasks plus removal and installation are described for the Transmissions. click here.....


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 Apr 2003 aka Toyota Harrier) motors: 2.4 litre (2362 cubic centimetre ) "2AZ-FE" Dual Overhead Cam four cylinderinder petrol. 3.0 litre (2994 cubic centimetre ) "1MZ-FE" Dual Overhead Cam Vee Six petrol. 3.3 litre (3311 cubic centimetre ) "3MZ-FE" Dual Overhead Cam Vee Six petrol. Table of contents: Introduction Chapter 1: Tune-up and routine maintenance Chapter 2: Part A: Four-cylinder motor Chapter 2: Part B: Vee Six motors Chapter 2: Part C: General motor overhaul procedures Chapter 3: Cooling heating and air conditioning systems Chapter 4: Fuel and Exhaust pipess Chapter 5: motor wirings Chapter 6: Emissions and motor control systems Chapter 7: Automatic transaxle Chapter 8: Driveline Chapter 9: braking system Chapter 10: springs and shock absorbers and Rack and pinion systems Chapter 11: Body Chapter 12: Chassis wiring Wiring Diagrams Note does not cover Hybrids extra info

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

Announced in April 2000 on nyc automobile Show and showing up in late 2000 in Japan and January, 2001, in the united states, the Highlander became one of the primary car-based midsize SUV or midsize crossovers. The Highlander is the crossover equivalent to your much more rugged, truck-based midsize 4Runner and became Toyota's best-selling SUV before being surpassed by the smaller RAV4 in 2006. In Japan, the Kluger try exclusive to dealership community called Toyota NETZ as a larger replacement for the RAV4.

Unable to utilize the Highlander title in Japan and Australia because of a trademarked Hyundai Terracan trim line, Toyota calls the car the Toyota Kluger indeed there, the name based on the German term klüger, this means clever or sensible.

The Highlander shared a platform using its Lexus RX/Toyota Harrier cousin. They came in five and seven-seat configurations and became a sales profits for Toyota in several markets 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 rivals including the Jeep Grand Cherokee, or Chevrolet TrailBlazer, the Highlander directed for on-road benefits using its unit body construction and separate rear suspension. Though it was more than the 1996–2002 4Runner available at the time it was established, the Highlander is surpassed in total by the redesigned 4Runner in 2002.

The Highlander was for sale in three trim lines in the usa: the bottom design, the Sport design, additionally the minimal design. The beds base and minimal products were present as soon as the Highlander was initially introduced, even though the athletics design is launched in March 2006. In Japan, it's considered to be a luxury vehicle since the Kluger exceeds Japanese national regulations managing motor displacement and outside dimensions.

In 2004 the tires on brief trim changed from a six-spoke, to a five-spoke alloy. The base-model Highlander wheels in addition altered from steel-rims towards alloy wheels which were on 2001–2003 design seasons Highlander Limited and B-Package. The game versions have an exceptional grille design, distinguishing themselves from the non-Sport systems. Wheel styling furthermore acts to separate the different models—the hybrid sports a distinctive twin-spoke build.

The Kluger ended up being introduced to Australia during 2003. It had been for sale in three guises: CV, CVX, and Grande. A restricted edition CV athletics design was also introduced in 2006. There clearly was no crossbreed design obtainable in Australia. The only real motor provided ended up being the 3.3-liter 3MZ-FE V6.

The Toyota AZ system household was a straight-4 piston system series. The AZ series makes use of an aluminium engine block with cast-iron cylinder liners and aluminium DOHC cylinder heads. The motor show features numerous advanced level technology like slant-squish burning chambers, counterbalance cylinder and crank facilities, plus the VVT-i constantly variable intake valve time system. The aluminium system measures 626 mm very long, 608 mm wide, and 681 mm taller.

The cylinder block are an open-deck, midi-skirt die-cast aluminium type with cast-in metal liners and a die-cast aluminium lower crankcase and a stamped oil cooking pan. The forged metallic crankshaft are fully balanced with eight counterweights and supported by five biggest bearings. A helical gear pushed in #3 counterweight drives twin contra-rotating balance shafts in the shaft housing in the reduced crankcase.

The twin expense camshafts were driven by a single-stage roller string of 8.0 mm pitch, allowing a thin included valve position of 27.5°. The camshafts act on four valves per cylinder via bucket tappets. As in the recent Toyota motor rehearse, no clearance modifying shim is required. Valve diameters is 34.0 mm for intake and 29.5 mm for exhaust, with 8.0 mm raise both for consumption and exhaust. The four-vane VVT-i device is fitted from the intake camshaft, changing time by 50°. The device address is made of magnesium to save fat.

Fuel was injected sequentially via an ultra-fine-atomization injector with twelve tiny injection holes, each 0.18 mm in diameter. Like in small NZ engine, this new AZ adopts a plastic, built-up, and vibration-welded intake manifold integrating a sizable amount plenum chamber amount like a 1.3 L resonator). Fatigue manifolds tend to be of tubular building with built-in catalytic converters.

The AZ may be the replacement for the S engine. It will eventually feel changed by the AR engine.
As well as the 3.3-liter system, 2004 V6-powered designs were designed with a brand new five-speed automated transmission, replacing a 4-speed automatic transmission, as the 4-cylinder systems proceeded to utilize the old 4-speed automatic transmission. In 2010 additionally saw the introduction of the recommended third line chair permitting two additional individuals. The unibody ended up being slightly modified behind the second row chairs to add a depression inside trunk area floors able to satisfy the optional third line seating. On products without third row sitting, this depression was changed into a storage storage space. Discreet modifications on front side grille, front side and back bumpers, and headlights round-out the major modifications for the 2004 mid-cycle refresh.

Starting in 2006, Highlanders marketed in Canada could be offered only in a V6 all-wheel drive setup. Crossbreed models are available with part-time four-wheel drive which Toyota describes as 4WD-i where in fact the rear wheels tend to be run on the individual electric engine. This system is intended to be used on snowfall and ice, and is susceptible to overheating the rear electric motor off road.
2003–2007 Toyota Kluger Grande, Australia

Japan and Australian Kluger was released with a center console incorporated utilizing the dashboard, although the us Highlander at first lacked this incorporated center console. The incorporated centre console had been launched in all U.S. Highlanders plus Canadian Limited Highlanders in 2002 design year, and in all Canadian Highlanders into the 2003 model season. But of these early Highlanders without having the built-in center system, a smaller non-integrated stand-alone centre console is readily available as a choice, that was set up at the factory or could be setup by the supplier.

Toyota revealed the second-generation Highlander and Highlander Hybrid within 2007 Chicago car Show, with US product sales starting in July and hybrids in belated September. Although second-generation Highlander and Highlander crossbreed aren't offered in Japan. The five-seat Highlander for the united states of america and Canada ended up being dropped whilst the larger Venza replaced they.

Initially the sole powertrain the 2008 Highlander is a 270 horsepower 3.5-liter 2GR-FE V6 mated to a five-speed automatic. The four-cylinder design had been stopped but added again in '09. Even though the 3.5-liter motor has 55 even more bhp compared to the past 3.3-liter V6 and dimensional increases and enhanced sound proofing added nearly 500 pounds to your car's curb weight of approximately 4,000 pounds, fuel economic climate was a little enhanced. The EPA calculated gas economic climate for front-wheel drive designs reaches 18 mpg-US town / 24 mpg-US highway town / 23 mpg-US hwy).

For 2009, Toyota again supplied a 4-cylinder for 5-passenger front-wheel drive systems with the all-new ULEV-II licensed 2.7-liter 1AR-FE I4 paired to a six-speed automated. It generates 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 provides an EPA predicted gasoline economy of 20 mpg-US town and 27 mpg-US highway. That is better than the earlier model's four-cylinder with 19 mpg-US/25 mpg-US.

The exact same three trim level were supplied until very early 2010 when the SE design changed the activity design, buyers will always be capable choose between front-drive or all-wheel drive on V6 systems. Additionally new try an electrical Power Steering system. Recreation and brief versions see a regular backup digital camera making use of a 3.5-inch LCD screen. Big alternatives incorporate leather-based chairs, heated seating, a touch-screen DVD centered navigation program, an innovative new Smart Key System, an upgraded JBL Synthesis stereo, a rear-seat DVD entertainment system with 9-inch display, and a towing package that grows towing ability to 5000 weight.

During XU40 generation, the Highlander/Kluger was created solely in Japan for several international areas on Kyūshū and Ikeda, Osaka assembly herbs starting in May 2007. Production in China for local purchases ended up being began may 25, 2009 by GAC Toyota in Nansha region, Guangzhou, Guangdong. Toyota have intended on creating the Highlander in Blue Springs, Mississippi for the united states markets in the 2011 design 12 months. But the Corolla had been built there rather, and the Highlander has been built at Toyota Motor production Indiana in Princeton, Indiana, from 2010 model seasons onward for a lot of the united states, replacing Tundra manufacturing. TMMI Highlander manufacturing began in October 2009 for gasoline engine brands only; hybrids stayed brought in from Japan before the release of the third generation XU50, in which all manufacturing with the exception of Asia had been consolidated at TMMI.

In Australian Continent, the latest generation Kluger was launched in August, 2007. There are three grades available, KX-R, KX-S and Grande. All grades can be obtained with either 2WD or AWD. The beds base design KX-R can be offered with either five or seven seating, as the second grades were seven seaters just. Specs are typically like the people Highlander, revealing equivalent 3.5-litre V6 2GR-FE system and five-speed automatic transmission. However, there are no programs at the moment to present a hybrid version of the Kluger in to the Australian markets.
2010 upgrade
Facelift Toyota Highlander

The 2011 model year, Toyota made some adjustment on Highlander and Highlander crossbreed. Although the general build continues to be just like the 2010 design, the Highlander's forward end has-been considerably modified, today featuring newer headlights, a brand new black colored with chrome accent rocker panel, and new front grille. The non-hybrid motors for 2011 remain the exact same, although today the 2.7-liter four-cylinder system might had from the SE trim degree, formerly just available on the base design. More standard qualities are now actually complete on all trim amount, utilizing the base model receiving front and rear air-con, power locks/windows, cruise control, and a multi-function keyless entry controls.
NHTSA crash test ranks: Frontal Driver: 5/5 performers
Front Passenger: 4/5 performers
Side Driver: 5/5 stars
Part Backside Traveler: 5/5 performers
Rollover: 4/5 stars

All designs come standard with improved automobile Stability Control which immediately alters electric powering steering assist w/traction controls, anti-lock brake system, brake support and electronic brakeforce distribution. In addition standard is a tire pressure track, a driver's leg airbag, front seat-mounted part body airbags, part curtain airbags for several three rows which include a rollover sensor and active front side headrests. Mountain begin aid controls is also standard which prevents moving backwards on slopes, and Downhill Assist controls try standard on AWD trims.

The IIHS rate the Highlander "close" overall inside their frontal offset crash test, and close in all subcategories with the exception of "Head/neck," which is rated as "Acceptable." And "great" overall in the side impact crash test, with "great" rating in every nine measured categories. The Highlander normally ranked "Good" within the roofing strength test, offering it a premier security Pick award.

In Australasian unique vehicles evaluation plan testing the Kluger is provided a 5/5 performers rating but just a 1/4 movie stars score for pedestrian defense.

The safety and effectiveness associated with Highlander/Kluger's automobile Stability Control system was questioned by some motoring journalists. During examination for rims mag Car of the Year in 2007, the mag's publisher rolled the vehicle during high-speed gravel road testing. Noting that it was the very first such event within the mag's 45-year records, he criticised the automobile's security program stating that "too little the Kluger's ESP added into crash". Six of the seven more judges in addition claimed they felt "the vehicle's ESP overall performance ended up being sub-standard", and remarked that automobile ended up being "almost dangerous on soil ". In a written responses, Toyota disputed the conditions regarding the accident and criticised the testing processes as "unscientific".

On March 27, 2013, Toyota launched the third-generation XU50 series Highlander during the New York International automobile program, with plans to have the vehicle get to dealerships at the beginning of 2014. Manufacturing started on December 5. This variation was much longer and wide versus outgoing generation as well as its design has changed from its boxy check out one that is comparable to more mid-size crossover SUVs.

Besides the changes, that one will showcase sitting for eight individuals with a sliding second-row point of entry that gives they 4.3 ins of added circumference room, soft-touch content on tool panel, lane-departure caution, pre-collision caution and blind area tracking methods. HD broadcast and Bluetooth will become a typical on all trims for United States variation, that will additionally come loaded with Toyota's Entune multimedia system along side a 6.1-inch touchscreen display speakers. An eight-inch touchscreen program and Toyota's Entune app package with 12 JBL speakers is supposed to be offered as an optional feature. The 3 powertrain trims which will be offered include a 2.7L/6-speed front-wheel drive base model, a 3.5L/6-speed 6AT design both in front-wheel or all wheel drive, therefore the AWD-only Hybrid trim with a 3.5L/V6 mated to an eCVT.

The modern Highlander can be authorized to be used as a brand new York City taxicab.

The Toyota Kluger mid-sized four-wheel drive hit the industry in October 2003, around three-years after they first appeared in North America, as well as 2 years following the right hand drive variation -- labeled as Highlander -- went on sale in Japan.

Toyota Australian Continent wished the Highlander title, but Hyundai -- which makes use of they as a grade name on the Terracan four-wheel drive -- wouldn't relinquish the moniker. Ergo Kluger, which will be said to indicate 'clever' or 'very smart' in German.

The Kluger was a deceptively big automobile, appearing in photographs is no bigger than a Subaru Forester. Actually, the Kluger was 4.7m very long, 1.83m wide and around 1.7m tall, rendering it between 10-25cm bigger than Forester in every proportions. A Commodore sedan, by comparison, is yet another 10cm longer than Kluger.

Kluger's fundamental truck bundle encompasses a robust 3.3-litre V6 motor mated to all wheel drive and highest crushed clearance. Toyota feels the Kluger, and cars want it, is the after that big part of Australian Continent. So much so that Toyota hopes to build a good enough business case to prevent importing and commence creating the vehicle at their Altona plant by 2007.

For the to take place Australians must showcase a yearly desire for food for 30,000 Klugers, or about 2500 monthly. Initially Toyota feels it may offer around 500 30 days, but wants razor-sharp goes up in deals and appeal when Holden's six-cylinder Adventra and Ford's area join the fray -- while increasing market visibility of crossover motors -- late in 2004.

Kluger's most appealing qualities tend to be truly their people-carrying capacity and on-road results, paired in a four-wheel drive system. The rise in popularity of traditional four-wheel drives has exploded phenomenally since 1990, due just as much to their high driving place and carrying capability concerning their off-road ability.

Toyota calls Kluger a car-based SUV, which "offers passenger car-like convenience and performance." We will just take a closer evaluate that declaration into the "on the way" part, but for today let's read the number.

Three models include the Kluger number in Australia -- CV, CVX and Grande -- with pricing beginning at $43,990 and topping out at $58,990. All three models promote exactly the same system and transmission bundle, specifically a 3.3-litre V6 mated to a five rate automated transmission. All three versions has all-wheel drive, technical regarding the CV and CVX and digital regarding Grande.

All Klugers feature power steering, cruise controls, weather control air-conditioning, tinted rear-side windows, journey computers, CD athlete and full-size extra wheel. Features and safety products enhance from model to model in track with all the price; the CVX and CVX would be the best value for cash, and so are expected to appeal to over 90 percent of consumers.

The bigger quality CVX adds alloy rims, roof rails and fog lights externally. Power front seats, a six-stack CD athlete and rear-seat heater settings supplement the inside.

Top grade Grande adds larger 17-inch tires, sunroof and a rear spoiler outdoors, touch-screen satellite navigation in. Besides, forward part airbags and curtain airbags, electronic four-wheel drive, traction control and vehicle security controls make the Grande the safest of all of the Klugers.

Toyota automobiles are nothing or even efficient and useful, sometimes towards the detriment of emotional destination. Irrespective, because they're furthermore supremely capable and keenly cost, and Klugerisn' various.

Interior space and qualities are unremarkable inside their effectiveness. Both front side and 2nd line of seating tend to be comfortable and roomy enough for a typical sized person. Leading chairs tend to be somewhat moulded to reduce body sliding, especially the backrest, though not enough for our preference. Headroom is good both in rows, and use of each is made effortless by broad orifice doors and vehicles's higher stance.

The third line of seating -- installed standard to CVX and Grande designs, recommended on CV -- try a kids-only domain names. Grownups will have trouble getting their bigger legs to the footwell, the level of which renders legs awkwardly higher. The 3rd line do fold perfectly level you should definitely used, releasing up plenty of baggage room within the boot area.

We had some trouble finding an appropriate operating position, despite the fact the driver's chair slides, tilts and raises. The controls just tilts, indicating the pedal to wheel proportion is always a compromise. Nevertheless, travel the automobile is no difficulties, exposure is very good throughout four instructions, and enormous wing mirrors are easy to utilize.

Swing-type arm rests regarding the two front side chairs be useful on longer trips.

Kluger's safety tale begins with its automobile characteristics, which are a lot more impressive and receptive than a traditional four-wheel drive's. Though not quite during the degree of a passenger car, Kluger's relative sure-footedness will increase chances of avoiding a collision.

All Klugers get all-wheel drive, along with anti-lock disc brakes with EBD and BA.

Car stability controls and grip control are standard regarding the Grande, a recommended additional regarding the CVX and never available on CV.

Passive security includes front airbags for driver and passenger and pretensioning seatbelts with force limiters. Kluger's bodyshell are said to be "highly rigid" by Toyota, which supplies both a stronger protective shell while the basis for a nimble and responsive framework.

Toyota states the Kluger is founded on the Lexus RX330 four-wheel drive, which makes this vehicle something of a cut-priced deluxe deal. Fundamental mechanicals including 3.3-litre V6 engine, five-speed automated transmission, four-wheel drive system and suspension is distributed to the upmarket Lexus.

Variable valve timing from the inlet valves are said to minimize gasoline usage and boost torque in lower revs and free up most energy in greater revs. Kluger's top power of 172kW and torque of 328Nm helps it be one of the most powerful six-cylinder crossover automobiles currently available.

Both CV and CVX share similar all wheel drive program which works through a viscous coupling centre differential and rear restricted slide diff. Torque is apportioned 50:50 front side to rear. The Grande eschews the viscous LSD at the heart for an electronically controlled traction controls program which Toyota claims "provides most accurate and smoother grip".

Four-wheel separate suspension system has been tuned primarily for on-road utilize, but Kluger's 184mm surface approval means it's going to cheerfully tackle simple to medium four-wheel drive tracks.

Kluger techniques the scales at 1740-1875kg with respect to the design. It's going to speed up from rest to 100km/h in a claimed 8.1 moments, and cover the very first 400m in 16.3 seconds. Fuel intake, measured relating to Australian Design Rule specifications, try 12.3 litres/100km on a combined city/hwy pattern.

Kluger's most obvious competitors are not available for sale during the time of writing -- Holden Adventra V6 and Ford Territory -- therefore it is ambiguous how it'll opposed to those two locally created cars.

Associated with the current crop of vehicles, Subaru Outback appear near with all-wheel drive and a six-cylinder drivetrain but does not promote seven chairs. Subaru Forester is another five-seat consideration, but just the turbocharged XT will match the results. Mitsubishi's Outlander is unfortunately outgunned inside organization.

Toyota feels people will also proceed to Kluger from conventional Aussie families vehicle. Indeed Toyota hopes that Kluger as well as its ilk will one-day swap Falcon and Commodore as the typical Aussie family members vehicle. High hopes, yet not without explanation.

Commodore and Falcon people looking towards huge four-wheel drives must look into the Kluger a compromise, this means Camry, Avalon and Magna may also drop consumers. So too will large four wheel drives like Toyota's own Prado, Mitsubishi Pajero, Nissan Pathfinder among others drop clients to Kluger's best on-road manners and much more compact body.

Kluger fulfils Toyota's claim of having more passenger car-like on-road ways than a four-wheel drive, but it is nonetheless some way off dealing with like a real traveler automobile. Extortionate bodyroll in corners try Kluger's main problem in an otherwise faultless repertoire.

Kluger handles bumps and ripples into the tarmac with sure-footed efficiency, never losing one step or troubling the controls. Taken to the side of tyre hold the Kluger pushes carefully broad once the tyres squeal their particular displeasure. At cruising speeds the Kluger's independent suspension provides a smooth unruffled trip to occupants enjoying the well-insulated cabin.

The 172kW V6 engine is much more than adequately worthy of this application, providing strong speed off the level, and do not lacking natural herbs on steeper climbs. They settles easily into a 100km/h cross-country jaunt, the engine sounds hardly registering in cabin. Kluger, like some other Toyota merchandise, is restricted to 180km/h -- which can be unlikely to be an issue on Australia's greatly policed roadways.

The five-speed automatic gearbox are hidden with its procedure, smoothly transiting amongst the gears. It really is reluctant to improve straight down, requiring an exaggerated drive from the throttle to motivate a cog-swap. For the people, like united states, which favor a bit more controls, Toyota provides handbook selection on all five gears via the overdrive button and 3-2-1.

Kluger's power-assisted steering are slow to wind in, calling for too much feedback when it comes to desired result. Weighting was in the too-light part of perfect, with little fat build-up under anxiety. It is precise, and cushions the driver well from road bumps, but lacks feel. Kluger's switching circle try a little larger than the typical family members sedan, but undoubtedly smaller than more big four wheel drives.

That is really just what the Kluger is about: A very good attempt to build a genuine crossover vehicle that successfully combines passenger vehicles characteristics and performance in a four-wheel drive. Is it really worth purchasing? Yes, if you're after a psuedo-four wheel drive for mostly urban use.

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