Toyota Kluger workshop repair manual australia Winch Books

Toyota Kluger workshop repair manual australia

The Highlander provided a system with its Lexus RX/Toyota Harrier cousin. The Highlander is for sale in three trim outlines in the us: the beds base design, the game model, in addition to Limited design. In 2004 the wheels on the brief


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 to go


do your own repairs
do your own repairs
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 more here.....

The Highlander provided a system with its Lexus RX/Toyota Harrier cousin. It came in five and seven-seat configurations and became a sales success for Toyota in a number of markets around the world. The Highlander came standard with front wheel drive and provided all wheel drive. Unlike Toyota's very own 4Runner along with other mid-sized competition for instance the Jeep Grand Cherokee, or Chevrolet TrailBlazer, the Highlander directed for on-road convenience with its unibody construction and separate rear suspension. Though it had been more than the 1996–2002 4Runner offered by the full time it was launched, the Highlander ended up being exceeded long because of the redesigned 4Runner in 2002.

The Highlander is for sale in three trim outlines in the us: the beds base design, the game model, in addition to Limited design. The bottom and restricted brands had been current when the Highlander was initially launched, whilst the athletics model was launched in March 2006. In Japan, it's considered a luxury vehicle as Kluger surpasses Japanese national laws regulating system displacement and outside measurements.

In 2004 the wheels on the brief trim altered from a six-spoke, to a five-spoke alloy. The base-model Highlander wheels additionally changed from steel-rims to your alloy wheels that were from the 2001–2003 design season Highlander Limited and B-Package. The Sport systems had an exceptional grille build, differentiating on their own from the non-Sport versions. Wheel styling furthermore serves to distinguish the many models—the crossbreed sports a distinctive twin-spoke build.

The Kluger ended up being launched to Australian Continent in October 2003. It absolutely was for sale in three guises: CV, CVX, and Grande. A restricted edition CV athletics model was also circulated in 2006. There is no hybrid design obtainable in Australian Continent. Really the only motor supplied had been the 3.3-liter 3MZ-FE V6. Typical fuel economy using the Australian standard evaluating regime was 12.3 L/100 km.


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 motor managed to propel the Kluger from 0–60 mph in around 8.8 seconds. In 2004 the Kluger was handed a unique 3.3-liter V6 system to take on the more powerful V6 offerings from the competition, primarily the Nissan Murano as well as the Honda Pilot. The larger system made it easy for the Kluger to attain 0 to 60 miles per hour in 7.8 moments.

The Toyota Highlander, also known as the Toyota Kluger, try a midsize crossover SUV from Toyota. It's built on the exact same system as applied to the Toyota Camry.

Announced in April 2000 during the nyc automobile program and showing up in belated 2000 in Japan and January 2001 in North America, the Highlander became one of the primary car-based mid-size SUV or mid-size crossovers. The Highlander could be the crossover equivalent on much more tough, truck-based midsize 4Runner and became Toyota's best-selling SUV before being exceeded because of the smaller RAV4 in 2006. In Japan, the Kluger was unique to dealership network labeled as Toyota NETZ as a bigger option to the RAV4.

Incapable of utilize the Highlander title in Japan and Australia considering a trademarked Hyundai Terracan trim line, Toyota calls the automobile the Toyota Kluger there, title based on the German word klug, which means that smart or sensible.

The Japanese and Australian Kluger was launched with a center console incorporated with all the dashboard, although the united states Highlander initially lacked this incorporated center system. The integrated center system had been introduced throughout U.S. Highlanders as well as in Canadian restricted Highlanders in 2001, for 2002 design season, and in all Canadian Highlanders in 2002, the 2003 design season. However, for those early Highlanders with no built-in center system, a smaller non-integrated stand-alone center system is available as an alternative, that was set up within factory or might be put in because of the supplier.

In 2003, for the 2004 model 12 months, as well as the 3.3-liter motor, V6-powered brands were built with an innovative new five-speed automated transmission, replacing the four-speed automatic transmission, even though the inline-four systems continuing to make use of the old four-speed. In 2010 furthermore saw the introduction of the recommended 3rd row chair enabling two further people. The guts system, which was earlier unique into the top trim level, happens to be standard across all trims. The unibody was a little changed behind the next row seating to include a depression into the trunk flooring in a position to satisfy the optional 3rd row seating. On systems without 3rd row sitting, this despair is converted into a storage area. Discreet adjustment into front grille, front and back bumpers, headlights and taillights round-out the main modifications for 2003 mid-cycle refresh.
2005 up-date

In 2005, for 2006 model seasons, Highlanders offered in Canada are offered best in a V6 all-wheel drive setup. Crossbreed models are available with part-time four-wheel drive which Toyota describes as 4WD-i where rear wheels were powered by the individual electric engine. This method is supposed to be used on snow and ice, and is vulnerable to overheating a corner electric motor off road.

Anti-lock brakes, braking system aid and electronic brakeforce distribution had been standard, Vehicle Stability Control w/traction control recommended on 2001–03 products became standard for 2004 models. Furthermore standard for 2004 is a tire force monitor. Forward seat-mounted part torso airbags had been optional on 2001–06 brands, while front and 2nd row part curtain airbags were recommended on 2004–06 brands. Part airbags became standard on 2007 systems and also the curtain airbags gained a rollover sensor that 12 months too.

Toyota unveiled the second-generation Highlander and Highlander Hybrid at the 2007 Chicago automobile tv show, with US purchases beginning in July and hybrids in late September. But the 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 fallen while the bigger Venza changed it.

In the beginning the only powertrain for the 2008 Highlander had been a 270 horsepower 3.5-liter 2GR-FE V6 mated to a five-speed automatic. The four-cylinder design was in fact stopped but included once more last year. Whilst 3.5-liter motor has 55 additional bhp as compared to past 3.3-liter V6 and dimensional increases with increased sound proofing added nearly 500 pounds towards the automobile's curb pounds of approximately 4,000 lbs, gasoline economic climate are a little enhanced. The EPA determined gasoline economic climate for front-wheel drive designs reaches 18 mpg‑US city / 24 mpg‑US highway town / 23 mpg‑US hwy).

For 2009, Toyota again provided a 4-cylinder for 5-passenger front-wheel drive systems using 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 projected gas economy of 20 mpg‑US town and 27 mpg‑US highway. This is a lot better than the last model's four-cylinder with 19 mpg‑US/25 mpg‑US.

Exactly the same three trim amount had been provided until very early 2010 as soon as the SE design changed the activity model, purchasers will always be capable select from front-drive or all-wheel drive on V6 platforms. Furthermore latest are a power energy Steering system. Sport and brief brands have a standard back-up camera making use of a 3.5-inch LCD screen. Major options feature leather-based seats, heated seats, a touch-screen DVD created navigation program, a unique practical Key System, an upgraded JBL Synthesis stereo, a rear-seat DVD activities system with 9-inch display, and a towing bundle that grows pulling ability to 5000 lbs.

The XU40 was initially produced exclusively on Miyata plant in Miyawaka, Fukuoka, Japan for all global markets starting in May 2007. Manufacturing in Asia for regional selling had been began on 25 might 2009 by GAC Toyota in Nansha District, Guangzhou, Guangdong. Toyota have intended on creating the Highlander in Blue Springs, Mississippi for united states markets into the 2011 model year. But the Corolla is built indeed there as an alternative, and also the Highlander is being built at Toyota engine Manufacturing Indiana in Princeton, Indiana, from 2010 model seasons forward for a lot of North America, replacing Tundra production. TMMI Highlander production began in October 2009 for gas system models only; hybrids continued to be brought in from Japan before launch of the third generation XU50, in which all manufacturing excluding China ended up being consolidated at TMMI.

In Australia, the new generation Kluger was launched in August, 2007. You can find three grades available, KX-R, KX-S and Grande. All grades can be obtained with either 2WD or AWD. The bottom design KX-R can be offered with either five or seven seating, as the latter grades tend to be seven seaters just. Requirements are mostly similar to the US Highlander, revealing the same 3.5-litre V6 2GR-FE engine and five-speed automated transmission. But there are not any projects at present to present a hybrid version of the Kluger in to the Australian marketplace.

In 2010, for 2011 model season, Toyota made some adjustment on Highlander and Highlander Hybrid. Whilst basic build stays similar to the 2010 design, the Highlander's forward end happens to be notably revised, now featuring newer headlights, a fresh black with chrome accent rocker panel, and new-front grille. The non-hybrid machines for 2011 remain equivalent, although now the 2.7-liter four-cylinder motor might have from the SE trim levels, earlier best on the bottom design. Considerably standard qualities are actually prepared on all trim amount, utilizing the base model obtaining front and rear ac, power locks/windows, cruise control, and a multi-function keyless entry control.

All models come standard with improved Vehicle Stability Control which straight away alters electric powering steering assist w/traction control, anti-lock brake system, braking system aid and electronic brakeforce circulation. Additionally standard was a tire pressure monitor, a driver's leg airbag, front seat-mounted part body airbags, part curtain airbags for many three rows including a rollover sensor and energetic front side headrests. Slope Start Assist controls normally standard which stops rolling backwards on mountains, and Downhill help Control try standard on AWD trims.

The IIHS rates the Highlander "great" total in their front offset crash test, and great in all subcategories excluding "Head/neck," which can be ranked as "appropriate." And "close" total when you look at the part influence crash test, with "Good" rating in most nine assessed groups. The Highlander can be ranked "great" when you look at the roofing energy test, offering they a "top protection choose" rating.

In Australasian New vehicle Assessment system testing the Kluger is offered a 5/5 performers rating but just a 1/4 performers rating for pedestrian protection.

The security and results for the Highlander/Kluger's automobile security Control program is questioned by some motoring reporters. During assessment for tires mag vehicle of the Year in 2007, the magazine's publisher rolled the automobile during high-speed gravel road-testing. Noting that it was the first these types of celebration inside mag's 45-year background, he criticised the automobile's security program stating that "zero the Kluger's ESP contributed towards the crash". Six of the seven various other judges in addition reported they believed "the car's ESP overall performance was sub-standard", and remarked that the vehicle ended up being "almost dangerous on dust ". In a written reaction, Toyota disputed the situations associated with accident and criticised the assessment treatments as "unscientific".

On March 27, 2013, Toyota revealed the third-generation XU50 show Highlander on nyc International automobile tv show, with plans to possess automobile get to dealerships at the beginning of 2014. Production started on December 5. This variation try longer and wide as compared to outbound generation and its build has changed from its boxy aim to one that is much like various other mid-size crossover SUVs.

As well as the modifications, this will feature sitting for eight individuals with a sliding second-row point of entry that offers it 4.3 ins of added circumference area, soft-touch products regarding the instrument panel, lane-departure caution, pre-collision caution and blind place monitoring techniques. HD Radio and Bluetooth will become a standard on all trims the United States variation, that will additionally come built with Toyota's Entune multimedia system along side a 6.1-inch touchscreen show audio system. An eight-inch touchscreen program and Toyota's Entune software collection with 12 JBL speakers are supplied as an optional function. The three powertrain trims which is offered include a 2.7-liter, six-speed automated, front-wheel drive base design, a 3.5-liter, six-speed automatic model both in front- or all-wheel drive, additionally the AWD-only crossbreed trim with a 3.5-liter V6 mated to an eCVT.

A refreshed 2017 model year Highlander made an appearance during the March 2016 New York car Show with marketing starting when you look at the 4th quarter of 2016. In V6 driven products, an eight-speed automated replaced the six-speeder and modified V6 motor added Toyota's D4-S direct injection gas system. The newest Highlander features an innovative new fascia with restyled headlights and taillights, newer SE quality, and XLE and LE Hybrid grades plus brand new external and interior colors.

The Toyota Kluger mid-sized four-wheel drive hit the market in October 2003, around three-years after they initially starred in united states, as well as 2 many years following the right hand drive variation -- known as Highlander -- proceeded sale in Japan.

Toyota Australia desired the Highlander name, but Hyundai -- which makes use of it as a quality title regarding the Terracan four-wheel drive -- wouldn't relinquish the moniker. For this reason Kluger, which will be thought to indicate 'clever' or 'very clever' in German.

The Kluger try a deceptively huge car, showing up in photos to be no larger than a Subaru Forester. Actually, the Kluger is 4.7m very long, 1.83m wide and around 1.7m tall, which makes it between 10-25cm bigger than Forester in all dimensions. A Commodore sedan, in comparison, is yet another 10cm more than Kluger.

Kluger's basic truck package surrounds a powerful 3.3-litre V6 system mated to all the wheel drive and high surface clearance. Toyota feels the Kluger, and motors like it, will be the after that larger part of Australian Continent. So much so that Toyota hopes to build a great sufficient company instance to avoid importing and begin producing the vehicle at its Altona plant by 2007.

For the to happen Australians must show a yearly appetite for 30,000 Klugers, or just around 2500 per month. Initially Toyota thinks it could offer around 500 four weeks, but wants razor-sharp goes up in selling and appeal when Holden's six cylinder Adventra and Ford's area join the fray -- and increase marketplace publicity of crossover motors -- belated in 2004.

Kluger's many attractive properties were certainly their people-carrying ability and on-road performance, coupled in a four-wheel drive human anatomy. The popularity of old-fashioned four-wheel drives is continuing to grow phenomenally since 1990, due just as much with their higher driving position and carrying capacity on their off-road potential.

Toyota calls Kluger a car-based SUV, which "offers traveler car-like convenience and gratification." We'll simply take a closer view that report in "on your way" section, however for now let's browse the number.

Three systems comprise the Kluger number in Australian Continent -- CV, CVX and Grande -- with rates starting at $43,990 and topping-out at $58,990. All three brands promote exactly the same motor and transmission bundle, particularly a 3.3-litre V6 mated to a five speed automated transmission. All three models have all-wheel drive, technical on the CV and CVX and digital in the Grande.

All Klugers feature power steering, cruise control, weather control air-conditioning, tinted rear-side windows, travel computers, CD player and full size spare wheel. Qualities and security products enhance from design to model in track with the price; the CVX and CVX are the affordable for money, and tend to be anticipated to attract more than 90 percent of consumers.

The higher grade CVX adds alloy tires, roof rails and fog lighting externally. Energy front side chairs, a six-stack CD player and rear-seat heater controls supplement the inner.

Top grade Grande adds larger 17-inch tires, sunroof and a back spoiler outdoors, touch-screen satellite navigation inside. Furthermore, forward side airbags and curtain airbags, electronic four-wheel drive, traction controls and car security control make the Grande the safest of Klugers.

Toyota automobiles are nothing or even efficient and practical, sometimes to your detriment of mental attraction. Irrespective, since they're furthermore supremely able and keenly cost, and Kluger's no different.

Indoor room and services is unremarkable in their effectiveness. The front side and 2nd line of seating is comfortable and roomy enough for an average sized adult. Leading seats were somewhat moulded to cut back system sliding, specially the backrest, though insufficient for the taste. Headroom is good both in rows, and accessibility each is manufactured simple by wide opening doors and vehicle's large position.

The 3rd row of seats -- fitted standard to CVX and Grande products, optional on CV -- try a kids-only domains. Grownups has difficulty getting their particular bigger legs in to the footwell, the depth that departs knees awkwardly high. The third row does fold completely flat you should definitely being used, freeing up a lot of luggage space into the boot location.

We'd some trouble finding a comfy travel position, despite the fact the driver's seat slides, tilts and increases. The tyre just tilts, indicating the pedal to wheel ratio is obviously a compromise. That said, operating the automobile isn't any difficulties, visibility is excellent in most four directions, and enormous wing mirrors are easy to use.

Swing-type supply rests in the two front seats come in handy on longer trips.

Kluger's protection tale begins with their automobile characteristics, which are more impressive and receptive than a conventional four-wheel drive's. Though not quite within standard of a passenger vehicle, Kluger's relative sure-footedness will increase likelihood of avoiding a collision.

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

Vehicle stability control and traction controls tend to be standard on the Grande, an optional additional regarding CVX and not on CV.

Passive safety include forward airbags for motorist and passenger and pretensioning seatbelts with energy limiters. Kluger's bodyshell was said to be "highly rigid" by Toyota, which gives both a strong protective shell as well as the foundation for a nimble and receptive chassis.

Toyota states the Kluger is dependent on the Lexus RX330 four-wheel drive, making this vehicle anything of a cut-priced deluxe steal. Fundamental mechanicals such as for example 3.3-litre V6 motor, five-speed automated transmission, four-wheel drive program and suspension system is distributed to the upmarket Lexus.

Variable valve time in the inlet valves was believed to reduce gasoline consumption and boost torque in lower revs and release even more power in higher revs. Kluger's peak power of 172kW and torque of 328Nm makes it one of the more effective six-cylinder crossover cars at this time available.

The CV and CVX promote the exact same all wheel drive program which works through a viscous coupling centre differential and back limited slide diff. Torque is apportioned 50:50 front side to rear. The Grande eschews the viscous LSD at the heart for an electronically managed grip controls system which Toyota states "provides considerably accurate and smoother traction".

Four-wheel separate suspension has-been tuned primarily for on-road utilize, but Kluger's 184mm surface clearance implies it will gladly tackle very easy to moderate four-wheel drive tracks.

Kluger strategies the scales at 1740-1875kg with respect to the model. It will speed up from sleep to 100km/h in a claimed 8.1 seconds, and cover the initial 400m in 16.3 moments. Gas usage, measured according to Australian Design Rule specifications, try 12.3 litres/100km on a combined city/hwy cycle.

Kluger's biggest rivals are not on sale during the time of writing -- Holden Adventra V6 and Ford Territory -- therefore it is uncertain exactly how it's going to not in favor of those two in your area created cars.

Regarding the existing crop of vehicles, Subaru Outback comes close with all-wheel drive and a six-cylinder drivetrain but will not promote seven seats. Subaru Forester is yet another five-seat consideration, but only the turbocharged XT will complement the efficiency. Mitsubishi's Outlander try sadly outgunned in this organization.

Toyota thinks individuals will furthermore relocate to Kluger through the traditional Aussie families vehicle. In fact Toyota hopes that Kluger as well as its ilk will one-day substitute Falcon and Commodore as the typical Aussie family automobile. High hopes, yet not without factor.

Commodore and Falcon owners considering big four wheel drives must look into the Kluger a compromise, consequently Camry, Avalon and Magna will miss subscribers. So also will spacious four wheel drives like Toyota's very own Prado, Mitsubishi Pajero, Nissan Pathfinder and others drop subscribers to Kluger's much better on-road ways and more lightweight system.

Kluger fulfils Toyota's claim of experiencing even more traveler car-like on-road ways than a four-wheel drive, but it's nevertheless somewhat way-off managing like a genuine passenger car. Excessive bodyroll in corners is Kluger's main problem in an otherwise faultless arsenal.

Kluger manages lumps and ripples in the tarmac with sure-footed effectiveness, never dropping a step or troubling the controls. Taken to the edge of tyre hold the Kluger pushes gently large due to the fact tyres squeal their displeasure. At cruising speeds the Kluger's separate suspension delivers a smooth unruffled ride to occupants experiencing the well-insulated cabin.

The 172kW V6 engine is much more than properly suited to this application, offering strong acceleration 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 barely registering in the cabin. Kluger, like other Toyota products, is restricted to 180km/h -- that will be unlikely is a problem on Australia's heavily policed roads.

The five-speed automated gearbox are hidden in its operation, efficiently transiting amongst the gears. It's hesitant to improve down, requiring an exaggerated drive on throttle to motivate a cog-swap. For all those, like united states, which choose a little more control, Toyota provides manual selection on all five gears through the overdrive key and 3-2-1.

Kluger's power assisted steering is sluggish to breeze on, requiring too much feedback for desired result. Weighting try regarding the too-light side of best, with little to no fat build under anxiety. It's accurate, and cushions the motorist well from roadway bumps, but lacks experience. Kluger's turning group is somewhat larger than the typical family sedan, but definitely smaller compared to many larger four-wheel drives.

Which is really just what the Kluger is all about: a good attempt to build a true crossover car that successfully combines passenger vehicles characteristics and performance in a four-wheel drive. Will it be well worth buying? Yes, if you should be after a psuedo-four wheel drive for mainly metropolitan usage.

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