Kluger Toyota repair workshop manual Indigo Books

Kluger Toyota repair workshop manual

The Toyota Highlander, also referred to as the Toyota Kluger, are a midsize crossover SUV from Toyota. Launched in April 2000 during the New York automobile tv show and arriving in belated 2000 in Japan and January, 2001, in united states,

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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. information

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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 click the link

The Toyota Highlander, also referred to as the Toyota Kluger, are a midsize crossover SUV from Toyota. It's constructed on the platform regarding the Toyota Camry.

Launched in April 2000 during the New York automobile tv show and arriving in belated 2000 in Japan and January, 2001, in united states, the Highlander became one of the primary car-based midsize SUV or midsize crossovers. The Highlander is the crossover counterpart into the more durable, truck-based midsize 4Runner and became Toyota's best-selling SUV before being exceeded by the modest RAV4 in 2006. In Japan, the Kluger was exclusive to dealership community labeled as Toyota NETZ as a more substantial option to the RAV4.

Unable to make use of the Highlander name in Japan and Australia due to a trademarked Hyundai Terracan trim line, Toyota calls the car the Toyota Kluger indeed there, title based on the German keyword klüger, which means that clever or sensible.

The Highlander shared a system using its Lexus RX/Toyota Harrier relative. It emerged in five and seven-seat designs and became a sales profits for Toyota in a number of areas around the world. The Highlander emerged standard with front wheel drive and provided all wheel drive. Unlike Toyota's very own 4Runner along with other mid-sized competition including the Jeep Grand Cherokee, or Chevrolet TrailBlazer, the Highlander directed for on-road benefits having its product system construction and separate rear suspension system. Even though it had been more than the 1996–2002 4Runner available at enough time it had been established, the Highlander was surpassed in total because of the redesigned 4Runner in 2002.

The Highlander was obtainable in three trim lines in the usa: the beds base design, the activity model, plus the minimal design. The base and Limited brands are present if the Highlander was initially launched, whilst athletics model is introduced in March 2006. In Japan, it's viewed as an extravagance car due to the fact Kluger surpasses Japanese federal government laws regulating system displacement and outside dimensions.

In 2004 the tires in the brief trim altered from a six-spoke, to a five-spoke alloy. The base-model Highlander rims additionally altered from steel-rims to the alloy rims which were regarding the 2001–2003 design season Highlander restricted and B-Package. The Sport systems had a unique grille design, distinguishing on their own from non-Sport systems. Wheel styling also acts to differentiate various models—the crossbreed sports a unique twin-spoke build.

The Kluger had been launched to Australian Continent during 2003. It had been obtainable in three guises: CV, CVX, and Grande. A small version CV athletics model has also been revealed in 2006. There was clearly no hybrid model for sale in Australian Continent. The actual only real motor provided was the 3.3-liter 3MZ-FE V6.

Machines:

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 managed to propel the Kluger from 0–60 mph in approximately 8.8 seconds. In 2004 the Kluger was presented with a unique 3.3-liter V6 system to contend with the more effective V6 offerings from its competitors, mainly the Nissan Murano and also the Honda Pilot. The more expensive system caused it to be feasible for the Kluger to reach 0 to 60 mph in 7.8 seconds.

The Toyota AZ engine household was a straight-4 piston system series. The AZ series makes use of an aluminium system block with cast iron cylinder liners and aluminium DOHC cylinder heads. The system series features many advanced technologies like slant-squish burning chambers, counterbalance cylinder and crank centers, in addition to VVT-i continuously adjustable intake valve timing program. The aluminum engine actions 626 mm very long, 608 mm wider, and 681 mm high.

The cylinder block was an open-deck, midi-skirt die-cast aluminum type with cast-in iron liners and a die-cast aluminium lower crankcase and a stamped oils pan. The forged metal crankshaft is fully balanced with eight counterweights and supported by five main bearings. A helical equipment pressed in number 3 counterweight drives twin contra-rotating stability shafts in shaft housing in the reduced crankcase.

The double expense camshafts is driven by a single-stage roller chain of 8.0 mm pitch, allowing a narrow included valve perspective of 27.5°. The camshafts work on four valves per cylinder via container tappets. Like in the recent Toyota system rehearse, no approval adjusting shim is required. Device diameters become 34.0 mm for consumption and 29.5 mm for exhaust, with 8.0 mm lift for both intake and exhaust. The four-vane VVT-i unit is fitted regarding the intake camshaft, changing timing by 50°. The device cover is made of magnesium to save lots of pounds.

Fuel try injected sequentially via an ultra-fine-atomization injector with twelve small injection holes, each 0.18 mm in diameter. As with the smaller NZ motor, the latest AZ adopts a plastic, built-up, and vibration-welded intake manifold integrating a big volume plenum chamber volume like a 1.3 L resonator). Exhaust manifolds were of tubular construction with integrated catalytic converters.

The AZ could be the alternative to the S engine. It's going to be replaced because of the AR motor.

Toyota unveiled the second-generation Highlander and Highlander crossbreed during the 2007 Chicago Auto Show, with United states deals beginning in July and hybrids in belated September. Nevertheless the second-generation Highlander and Highlander crossbreed aren't marketed in Japan. The five-seat Highlander for united states of america and Canada was fallen given that bigger Venza replaced it.

At first the sole powertrain when it comes to 2008 Highlander is a 270 horse power 3.5-liter 2GR-FE V6 mated to a five-speed automatic. The four-cylinder model have been discontinued but added again last year. Whilst 3.5-liter motor possess 55 most bhp compared to past 3.3-liter V6 and dimensional improves along with increased sound proofing included almost 500 lbs to your car's curb body weight of around 4,000 lbs, gas economic climate are slightly improved. The EPA approximated gas economy for front-wheel drive versions are at 18 mpg-US city / 24 mpg-US highway town / 23 mpg-US hwy).

For 2009, Toyota once again provided a 4-cylinder for 5-passenger front-wheel drive products aided by the all-new ULEV-II qualified 2.7-liter 1AR-FE I4 paired to a six-speed automatic. It creates 187 hp at 5,800 rpm and 186 lb·ft of peak torque at 4,100 rpm on regular 87 octane fuel. The four-cylinder delivers an EPA predicted gasoline economy of 20 mpg-US city and 27 mpg-US highway. This is better than the previous design's four-cylinder with 19 mpg-US/25 mpg-US.

The exact same three trim level had been offered until very early 2010 whenever SE design replaced the Sport model, buyers continue to be able to choose from front-drive or all-wheel drive on V6 systems. Also newer are an Electric Power Steering program. Athletics and brief systems see a standard back up digital camera making use of a 3.5-inch Liquid Crystal Display show. Major alternatives integrate leather-based chairs, heated seats, a touch-screen DVD founded navigation program, a unique Smart Key program, an upgraded JBL Synthesis stereo, a rear-seat DVD activity program with 9-inch display, and a towing package that increases towing capacity to 5000 weight.

The XU40 was produced solely in Japan for several international areas starting in May 2007. LHD production taken place at the Miyata plant in Miyawaka, Fukuoka, with Daihatsu's Ikeda plant in Ikeda, Osaka producing for RHD markets. Manufacturing in China for neighborhood sales had been going on 25 might 2009 by GAC Toyota in Nansha area, Guangzhou, Guangdong. Toyota have intended on design the Highlander in azure Springs, Mississippi the united states market when you look at the 2011 model 12 months. But the Corolla is built indeed there as an alternative, and the Highlander will be built at Toyota Motor Manufacturing Indiana in Princeton, Indiana, from 2010 design seasons forward for a majority of the the united states, changing Tundra manufacturing. TMMI Highlander manufacturing began in October 2009 for gas system systems only; hybrids continued to be imported from Japan before the launch of the third generation XU50, where all production with the exception of China ended up being consolidated at TMMI.

In Australia, the brand new generation Kluger premiered in August, 2007. You will find three grades readily available, KX-R, KX-S and Grande. All grades can be found with either 2WD or AWD. The base model KX-R normally available with either five or seven seats, as the second grades are seven seaters only. Requirements are typically just like the United States Highlander, revealing similar 3.5-litre V6 2GR-FE engine and five-speed automated transmission. However, there are not any plans at present to introduce a hybrid form of the Kluger into the Australian marketplace.

Electrical power assisted steering or motor-driven power steering utilizes an electrical engine to aid the driver of a vehicle. Sensors detect the position and torque of the steering line, and a computer component is applicable assistive torque through the engine, which links to either the steering gear or steering column. This permits different quantities of assist with be used based on operating problems. Designers can therefore modify steering-gear a reaction to variable-rate and variable-damping suspension system methods, optimizing ride, handling, and steering for every single vehicle. On Fiat team cars the total amount of assistance is controlled using a button known as "CITY" that switches between two different guide curves, many various other EPS systems need adjustable guide. These offer even more aid since the vehicle decelerates, much less at quicker rates.

a mechanical linkage between your steering wheel and also the steering gear are retained in EPAS. In case of component troubles or energy troubles that causes a deep failing to give you support, the technical linkage functions as a back-up. When EPAS fails, the driver encounters a predicament in which heavy efforts is required to steer. This heavier effort is comparable to compared to an inoperative hydraulic steering help system. With respect to the travel situation, driving ability and power of the motorist, steering assist control may or might not cause an accident. The issue of steering with inoperative energy steering are compounded by the range of steering ratios in assisted steering gears vs. completely handbook. NHTSA have assisted car producers, eg Ford, with remembering EPAS techniques susceptible to failure.

Electric techniques posses a benefit in fuel effectiveness since there is no belt-driven hydraulic pump constantly operating, whether aid is necessary or perhaps not, which are an important reason behind their introduction. Another significant benefit may be the elimination of a belt-driven motor accessories, and many high-pressure hydraulic hoses involving the hydraulic pump, mounted on the system, together with steering gear, installed on the framework. This significantly simplifies manufacturing and upkeep. By integrating electronic stability control electric power steering methods can instantly vary torque assist levels to aid the driver in corrective maneuvers.

The initial electric power steering system made an appearance regarding the Suzuki Cervo in 1988. The system is used by various car brands.

For the 2011 design season, Toyota made some adjustment towards the Highlander and Highlander Hybrid. As the basic build continues to be like the 2010 design, the Highlander's front end happens to be substantially modified, now featuring new headlights, a fresh black colored with chrome accent rocker panel, and new front grille. The non-hybrid motors for 2011 continue to be equivalent, although now the 2.7-liter four-cylinder motor might be have on SE trim degree, earlier just on the beds base design. More standard properties are now prepared on all trim level, with the base model receiving front side and rear ac, power locks/windows, cruise controls, and a multi-function keyless entry control.
Safety
NHTSA crash test ratings: Frontal motorist: 5/5 movie stars
Front Passenger: 4/5 performers
Side Motorist: 5/5 performers
Side Rear Traveler: 5/5 performers
Rollover: 4/5 movie stars

All designs come ordinary with better Vehicle security Control which straight away alters electric powering steering assist w/traction control, anti-lock brakes, braking system support and electronic brakeforce distribution. In addition standard are a tire force monitor, a driver's knee airbag, front seat-mounted side body airbags, side curtain airbags for several three rows which include a rollover sensor and active front side headrests. Hill begin aid Control is also standard which prevents rolling backwards on mountains, and Downhill support controls try standard on AWD trims.

The IIHS rate the Highlander "Good" overall within their frontal offset crash test, and close in most subcategories aside from "Head/neck," which will be rated as "Acceptable." And "great" overall within the side effects crash test, with "great" score in most nine measured categories. The Highlander normally ranked "close" within the roofing power test, giving it a high Safety choose honor.

In Australasian New Car Assessment plan testing the Kluger try provided a 5/5 stars rating but just a 1/4 stars rating for pedestrian coverage.

The safety and effectiveness regarding the Highlander/Kluger's automobile security controls program is asked by some motoring journalists. During assessment for tires magazine automobile of the season in 2007, the magazine's editor rolled the vehicle during high-speed gravel road testing. Noting that it was initial these types of event in the magazine's 45-year record, he criticised the vehicle's security system stating that "zero the Kluger's ESP added toward crash". Six of the seven more judges in addition reported which they sensed "the car's ESP overall performance ended up being sub-standard", and remarked that the automobile is "almost dangerous on dust ". In a written reaction, Toyota disputed the situations of crash and criticised the testing procedures as "unscientific".
Hybrid

On March 27, 2013, Toyota unveiled the third-generation XU50 show Highlander during the nyc worldwide Auto tv show, with intends to have the automobile reach dealerships in early 2014. Production started on December 5. This variation try longer and larger as compared to outgoing generation and its own design changed from the boxy check out one that's much like various other mid-size crossover SUVs.

Besides the modifications, that one will function seating for eight individuals with a sliding second-row point of entry that provides they 4.3 inches of added circumference area, soft-touch content regarding the tool panel, lane-departure caution, pre-collision warning and blind spot tracking systems. HD broadcast and Bluetooth will become a typical on all trims when it comes to US variation, that will also come equipped with Toyota's Entune media system and a 6.1-inch touchscreen screen sound system. An eight-inch touchscreen system and Toyota's Entune application collection with 12 JBL speakers may be offered as an optional function. The three powertrain trims that 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, as well as the AWD-only crossbreed trim with a 3.5L/V6 mated to an eCVT.

The newest Highlander can be authorized for usage as a unique York town taxicab.
The anti-lock brake controller can also be referred to as taxi.

Typically ABS includes a central electronic controls product, four wheel speed sensors, and at minimum two hydraulic valves inside the brake hydraulics. The ECU constantly tracks the rotational rate of each wheel; if it detects a wheel turning significantly slower compared to the others, a condition indicative of impending wheel lock, it actuates the valves to lessen hydraulic stress towards the braking system during the affected wheel, thus reducing the stopping power thereon wheel; the wheel after that transforms faster. Conversely, if ECU detects a wheel turning somewhat quicker versus other people, braking system hydraulic stress on wheel was increased so the braking force are reapplied, slowing the wheel. This process was recurring continuously and that can be recognized by the motorist via braking system pedal pulsation. Some anti-lock systems can apply or discharge braking force 15 occasions per 2nd. As a result of this, the rims of automobiles designed with ABS tend to be practically impossible to secure also during anxiety braking in extreme problems.

The ECU try set to disregard differences in wheel rotative speed below a vital threshold, because when the vehicle are turning, both tires towards the center associated with bend switch slower compared to outer two. With this same explanation, a differential is used in most roadgoing automobiles.

If a fault develops in almost any an element of the abdominal muscles, a caution light will usually feel illuminated regarding the automobile instrument panel, together with ABS is disabled before the fault is rectified.

Modern ABS applies individual brake stress to all the four tires through a controls system of hub-mounted detectors and a separate micro-controller. ABS is offered or comes standard on most road automobiles produced these days and it is the foundation for digital stability controls methods, that are rapidly rising in popularity because of the vast reduction in price of vehicle electronics through the years.

Modern electric security controls techniques become a development of the abdominal muscles idea. Here, no less than two additional detectors tend to be added to assist the system services: they're a steering wheel direction sensor, and a gyroscopic sensor. The theory of procedure is easy: when the gyroscopic sensor detects that the path taken because of the automobile will not coincide with what the steering wheel sensor states, the ESC applications will brake the necessary person wheel, so your car goes what sort of motorist intends. The tyre sensor additionally facilitates the operation of Cornering Brake Control, since this will inform the ABS that wheels within the bend should brake a lot more than tires externally, and also by just how much.

ABS gear doubles to implement a grip control program on speed for the car. If, whenever accelerating, the tire manages to lose grip, the ABS controller can detect the specific situation and bring appropriate activity to ensure traction is regained. Considerably advanced models with this may also manage throttle level and brakes at the same time.

The rate sensors of abdominal muscles are sometimes used in indirect tire force monitoring system, that could identify under-inflation of tire by difference between rotational rate of tires.

There are four main the different parts of ABS: wheel rate detectors, valves, a pump, and a controller.

Rate sensors
a speeds sensor is employed to determine the speed or deceleration of this wheel. These detectors need a magnetic and a Hall effect sensor, or a toothed wheel and an electromagnetic coil to create a signal. The rotation regarding the wheel or differential induces a magnetic area round the sensor. The fluctuations of the magnetic field produce a voltage into the sensor. Considering that the voltage induced in sensor is because the turning wheel, this sensor becomes inaccurate at slowly speeds. The slower rotation of this wheel can cause inaccurate changes into the magnetic field and thus cause inaccurate readings towards controller.
Valves
Discover a valve when you look at the brake line of each brake monitored by the ABS. On some systems, the device has actually three jobs:

Constantly in place one, the valve are open; pressure through the master cylinder try passed all the way through into brake.
In place two, the device blocks the line, isolating that braking system from the master cylinder. This stops pressure from rising more should the motorist push the braking system pedal harder.
In position three, the valve releases some of the force through the brake.

Nearly all difficulties with the device program take place considering blocked valves. When a valve was blocked its incapable of start, close, or changes place. An inoperable device will prevent the program from modulating the valves and controlling pressure provided to your brake system.

Pump
The pump in the abdominal muscles is used to bring back the pressure to your hydraulic brakes following the valves have revealed it. A signal through the operator will launch the valve during the recognition of wheel slip. After a valve release the pressure provided from consumer, the pump is used to bring back a desired level of pressure on stopping system. The operator will modulate the pumps reputation being give you the ideal quantity of force and minimize falling.
Operator
The operator are an ECU type product within the car which receives information from each individual wheel rate sensor, in turn if a wheel loses traction the sign are provided for the operator, the controller will likely then reduce brake energy and trigger the ABS modulator which actuates the braking valves off and on.
Digital security controls, also referred to as electric stability plan or dynamic stability controls, are a computerized tech that gets better a vehicle's stability by detecting and decreasing lack of traction. Whenever ESC detects loss in steering control, it automatically applies the brakes to simply help "steer" the automobile where in fact the driver intends to run. Braking are instantly applied to wheels independently, like the outer front-wheel to counter oversteer and/or inner back wheel to counter understeer. Some ESC techniques in addition minimize system power until controls is regained. ESC does not improve a vehicle's cornering performance; alternatively, it can help to reduce the increasing loss of controls. Based on Insurance Institute for Highway protection therefore the U.S. nationwide Highway visitors Safety Administration, one-third of deadly accidents could possibly be precluded by the usage technology.

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