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Toyota Kluger 2003-2014 Workshop manual

The Toyota Highlander, also referred to as the Toyota Kluger, is a midsize crossover SUV created by Toyota. It is built on the platform of the Toyota Camry.

Announced in April 2000 at New York car Show and showing up in belated 2000 in Japan and January, 2001, in united states, the Highlander became one of the first car-based midsize SUV or midsize crossovers. The Highlander may be the crossover equivalent into the much more rugged, truck-based midsize 4Runner and became Toyota's best-selling SUV before being surpassed because of the small RAV4 in 2006. In Japan, the Kluger was exclusive to dealership community called Toyota NETZ as a bigger alternative to the RAV4.

Unable to utilize the Highlander title in Japan and Australia as a result of a trademarked Hyundai Terracan trim line, Toyota calls the automobile the Toyota Kluger (pronounced Klu-ger) there, the name based on the German word klger, this means clever or wise.

The Highlander (or Kluger in Japan and Australian Continent) shared a platform having its Lexus RX/Toyota Harrier relative. It arrived in five (2001--2007) and seven-seat (2004--2007) designs and became a sales profits for Toyota in several markets around the world. The Highlander arrived traditional with front wheel drive and offered all wheel drive (50:50 front side:rear fixed torque split). Unlike Toyota's own 4Runner as well as other mid-sized competitors including the Jeep Grand Cherokee, or Chevrolet TrailBlazer, the Highlander aimed for on-road benefits with its product body construction and separate back suspension system. Even though it ended up being longer than the 1996--2002 4Runner offered by the time it had been launched, the Highlander is exceeded in total by the redesigned 4Runner in 2002.

The Highlander had been obtainable in three trim lines in the us: the bottom model, the game model, together with Limited design. The bottom and minimal designs were current as soon as the Highlander was introduced, although the Sport design ended up being introduced in March 2006. In Japan, it is considered to be a luxury vehicle while the Kluger surpasses Japanese Government laws managing system displacement and external proportions.

In 2004 the tires in the Limited trim altered from a six-spoke, to a five-spoke alloy. The base-model Highlander wheels additionally changed from steel-rims toward alloy rims that have been in the 2001--2003 model year Highlander brief and B-Package. The game models had an exceptional grille design, distinguishing themselves from the non-Sport designs. Wheel styling also acts to separate the various models---the hybrid recreations an original twin-spoke build.

The Kluger is launched to Australia during 2003. It was obtainable in three guises: CV, CVX, and Grande. A restricted edition CV recreation design has also been revealed in 2006. There is no hybrid model available in Australian Continent. The sole engine offered was the 3.3-liter 3MZ-FE V6.


2001--2007 2.4 L 2AZ-FE I4, 155 hp (119 kW)
2001--2003 3.0 L 1MZ-FE V6, 220 hp (164 kW)
2004--2007 3.3 L 3MZ-FE V6, 225 hp (172 kW)

The 3.0-liter system was able to propel the Kluger from 0--60 miles per hour in approximately 8.8 moments. In 2004 the Kluger was given a new 3.3-liter V6 engine to compete with the greater amount of effective V6 offerings from its competition, mainly the Nissan Murano additionally the Honda Pilot. The more expensive engine managed to get possible for the Kluger to reach 0 to 60 mph (97 km/h) in 7.8 seconds.

As well as the 3.3-liter system, 2004 V6-powered versions are loaded with a unique five-speed automated transmission, replacing a 4-speed automated transmission, as the 4-cylinder systems proceeded to make use of the older 4-speed automatic transmission. This present year furthermore saw the development of the optional 3rd line seat allowing for two extra guests. The unibody was somewhat customized behind the next row chairs to incorporate a depression in the trunk flooring able to accommodate the optional third line sitting. On models without 3rd row sitting, this anxiety was changed into a storage compartment. (ahead of 2004 the free tire had been accessible from inside the car where in actuality the third line seating would consequently be situated; starting in 2004 the spare tire is accessible from beneath the car.) Delicate modifications on front grille, front and rear bumpers, and headlights round-out the most important modifications when it comes to 2004 mid-cycle refresh.

Beginning in 2006, Highlanders sold in Canada are offered best in a V6 all-wheel drive setup. Crossbreed designs can be obtained with part-time four-wheel drive which Toyota identifies as 4WD-i in which the rear rims is run on the split electric motor. This system is intended to be used on snow and ice, and is vulnerable to overheating the rear electric motor off-road.
2003--2007 Toyota Kluger Grande, Australian Continent

The Japanese and Australian Kluger was released with a centre console integrated because of the dashboard, even though the us Highlander at first lacked this integrated center console. The built-in centre system was launched throughout U.S. Highlanders plus in Canadian restricted Highlanders in 2002 design seasons, and in all Canadian Highlanders in the 2003 design year. However, for those early Highlanders without built-in center system, a smaller sized non-integrated stand-alone centre console is available as an alternative, which was setup at the factory or could possibly be set up by the dealership.

Typical gas economic climate using the Australian standard evaluation regime try 12.3 L/100 kilometer

Toyota disclosed the second-generation Kluger and Kluger Hybrid during the 2007 Chicago car program, with US selling starting in July and hybrids in late September. But the second-generation Kluger and Kluger Hybrid are not offered in Japan. The five-seat Kluger when it comes to United States and Canada was fallen whilst the bigger Venza replaced it.

In the beginning the only real powertrain when it comes to 2008 Kluger had been a 270 horsepower (201 kW) 3.5-liter 2GR-FE V6 mated to a five-speed automatic. The four-cylinder design was stopped but included once again last year. Even though the 3.5-liter motor has actually 55 more bhp than the past 3.3-liter V6 and dimensional improves alongside increased noise proofing added almost 500 pounds towards automobile's curb weight of around 4,000 pounds, gasoline economic climate try somewhat enhanced. The EPA calculated gas economic climate for front-wheel drive versions is at 18 mpg-US (13 L/100 km; 22 mpg-imp) city / 24 mpg-US (9.8 L/100 km; 29 mpg-imp) highway (final gen: 17 mpg-US (14 L/100 kilometer; 20 mpg-imp) city / 23 mpg-US (10 L/100 kilometer; 28 mpg-imp) hwy).

For 2009, Toyota once again offered a 4-cylinder for 5-passenger front-wheel drive systems because of the all-new ULEV-II qualified 2.7-liter 1AR-FE I4 paired to a six-speed automated. It creates 187 hp (139 kW) at 5,800 rpm and 186 lb*ft (252 N*m) of peak torque at 4,100 rpm on regular 87 octane fuel. The four-cylinder brings an EPA believed gas economic climate of 20 mpg-US (12 L/100 kilometer; 24 mpg-imp) town and 27 mpg-US (8.7 L/100 kilometer; 32 mpg-imp) highway. That is much better than the earlier design's four-cylinder with 19 mpg-US (12 L/100 km; 23 mpg-imp)/25 mpg-US (9.4 L/100 kilometer; 30 mpg-imp).

The exact same three trim values had been offered (Base, athletics, and Limited) until early 2010 once the SE model replaced the Sport design, buyers will always be capable choose between front-drive or all-wheel drive on V6 platforms. Furthermore latest try a power Power Steering (EPS) system. Sport and brief products have a typical backup digital camera utilizing a 3.5-inch LCD show. Significant choices consist of leather seating, heated seating, a touch-screen DVD founded navigation program, an innovative new Smart Key program, an upgraded JBL Synthesis stereo, a rear-seat DVD activities system with 9-inch display, and a towing bundle that increases towing capacity to 5000 pounds.

During XU40 generation, the Kluger/Kluger was initially produced exclusively in Japan for all global areas at Kysh and Ikeda, Osaka construction herbs from May 2007. Manufacturing in China for regional product sales was going on May 25, 2009 by GAC Toyota in Nansha District, Guangzhou, Guangdong. Toyota have intended on design the Kluger in Blue Springs, Mississippi for the united states markets within the 2011 model season. However, the Corolla is built indeed there instead, additionally the Kluger is being built at Toyota Motor Manufacturing Indiana in Princeton, Indiana, from 2010 model 12 months forward for most the united states, changing Tundra manufacturing. TMMI Kluger manufacturing started in October 2009 for gas motor designs only; hybrids continued to be imported from Japan through to the release of the 3rd generation XU50, where all production aside from China had been consolidated at TMMI.

In Australian Continent, this new generation Kluger was released 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 model KX-R normally available with either five or seven seats, while the second grades are seven seaters best. Standards are mostly like the people Kluger, sharing the exact same 3.5-litre V6 2GR-FE motor and five-speed automated transmission. But there are not any programs at the moment to present a hybrid form of the Kluger into the Australian markets.
2010 modify
Renovation Toyota Kluger (US)

For 2011 model season, Toyota made some changes to the Kluger and Kluger crossbreed. Whilst the general design continues to be just like the 2010 model, the Kluger's front end is considerably revised, now featuring latest headlights, an innovative new black colored with chrome accent rocker panel, and new front grille. The non-hybrid machines for 2011 stays equivalent, although today the 2.7-liter four-cylinder engine are had on the SE trim amount, earlier only on the beds base model. More standard functions are now actually equipped on all trim amount, aided by the base design getting front and rear air-con, power locks/windows, cruise control, and a multi-function keyless entry control.
NHTSA crash test reviews (2008): Frontal Driver: 5/5 stars
Front Traveler: 4/5 stars
Part Driver: 5/5 performers
Part Backside Passenger: 5/5 movie stars
Rollover: 4/5 performers

All products come standard with improved Vehicle Stability Control which instantly alters electric powering steering assist w/traction controls (hybrids come standard with VDIM), anti-lock brake system, braking system support and digital brakeforce circulation. Furthermore standard is a tire force track, a driver's leg airbag, front seat-mounted side torso airbags, side curtain airbags for several three rows including a rollover sensor and active front headrests. Mountain begin guide Control (HAC) is also standard which stops rolling backwards on slopes, and Downhill Assist controls (DAC) try standard on AWD trims.

The IIHS rates the Kluger "close" overall within their front offset crash test, and close in all subcategories excluding "Head/neck," which is rated as "Acceptable." And "Good" total inside part effect crash test, with "great" rating in every nine assessed groups. The Kluger is also ranked "Good" in roofing energy test, offering they a high Safety choose award.

In Australasian unique vehicle evaluation plan (ANCAP) testing the Kluger is provided a 5/5 movie stars score but best a 1/4 performers score for pedestrian safeguards.

The safety and results regarding the Kluger/Kluger's Vehicle Stability controls program was asked by some motoring reporters. During evaluation for Wheels magazine vehicle of the Year in 2007, the magazine's editor rolled the vehicle during high-speed gravel road-testing. Noting that it was 1st such event when you look at the magazine's 45-year history, he criticised the vehicle's security system stating that "zero the Kluger's ESP added into the crash". Six regarding the seven various other judges also claimed they believed "the vehicle's ESP overall performance had been sub-standard", and remarked the vehicle was "almost dangerous on soil ". In a written responses, Toyota disputed the conditions regarding the accident and criticised the testing treatments as "unscientific".

The Toyota AZ motor family was a straight-4 piston engine series. The AZ show makes use of an aluminum engine block with cast-iron cylinder liners and aluminum DOHC cylinder heads. The system show features numerous advanced technologies including slant-squish combustion chambers, counterbalance cylinder and crank centers, and the VVT-i continually variable intake valve timing system. The aluminium engine measures 626 mm (25-in) lengthy, 608 mm (24-in) broad, and 681 mm (27-in) high.

The cylinder block is an open-deck, midi-skirt die-cast aluminum kind with cast-in iron liners and a die-cast aluminium reduced crankcase and a stamped oils pan. The forged metal crankshaft was totally balanced with eight counterweights and supported by five biggest bearings. A helical gear pressed in #3 counterweight drives twin contra-rotating balance shafts when you look at the shaft housing within the reduced crankcase.

The dual overhead camshafts become driven by a single-stage roller string of 8.0 mm (0.3-in) pitch, enabling a thin included valve perspective of 27.5. The camshafts act on four valves per cylinder via container tappets. Such as the latest Toyota system practise, no clearance modifying shim is utilized. Valve diameters were 34.0 mm (1.3 in) for consumption and 29.5 mm (1.2 in) for fatigue, with 8.0 mm (0.3-in) lift for both intake and fatigue. The four-vane VVT-i device is equipped regarding intake camshaft, altering timing by 50. The device cover consists of magnesium to save lots of fat.

Gas was inserted sequentially via an ultra-fine-atomization injector with twelve smaller injections holes, each 0.18 mm (0.01 in) in diameter. Like in small NZ system, the brand new AZ adopts a synthetic, built-up, and vibration-welded intake manifold integrating a large volume plenum chamber (3.5 L (214 in3) amount including a 1.3 L (79 in3) resonator). Exhaust manifolds is of tubular construction with incorporated catalytic converters.

The AZ could be the replacement the S system. It's going to feel replaced by the AR motor.

The Toyota MZ motor family members is a V6 piston system series. The MZ series features an aluminium system block and aluminum alloy DOHC cylinder minds. The cylinders is lined with cast iron, and it is of a closed deck design (no available space amongst the bores). The motor are a 60 level V6 build. They makes use of multiport gas injections (MFI), four valves per cylinder, a one-piece cast camshaft and a cast aluminum intake manifold. The MZ household is a lightweight V6 system of an all-aluminium build, using light body weight section compared to weightier task VZ block motors in order to reduced production costs, lessen engine pounds, and reduce reciprocating pounds without having to sacrifice dependability. Toyota looked for to boost the drivability design of motor (throughout the 3VZ) at precisely 3000 rpm, since that has been the conventional engine speeds for engines cruising on the highway. The result was less cylinder distortion plus the reduced body weight of rotating assemblies, smoother process at that motor rate, and enhanced engine effectiveness.

They showcase throw aluminium pistons with an anti-friction resin layer (moly) and valve depressions that reduce steadily the potential for valve-to-piston interference in the event of timing gear failure on engines without VVT-i. Additionally they make use of steel bands, smaller-diameter shot-peened rods, and a forged steel crankshaft.

This engine was eliminated generally in most markets, replaced by variants associated with the new GR series.

The 1MZ-FE is a 3.0 L (2994 cc) dual overhead cam (DOHC) V6 motor. Bore try 87.5 mm and swing try 83 mm. Output was 168--194 hp @ 5200--5400 rpm with 183--209 lb*ft of torque at 4400 rpm. Horse power reviews dropped after the community of auto designers implemented a energy measurement program for car motors, Toyota motors rated on 87 octane fallen the most, compared to the exact same engines utilized by Lexus ranked on 91 octane. This has bucket tappets and ended up being designed for good gas economy without a broad results trade-off. Over-all, these motors are very trustworthy if correctly maintained and can reach above 200,000 kilometers.

The 1MZ-FE is on Ward's 10 most useful machines checklist for 1996.


1993--2006 Toyota Camry (V6)
1993--2003 Lexus ES 300 & Toyota Windom (Japanese domestic markets)
1994--2004 Toyota Avalon & 2000 Toyota Pronard (Avalon for Japanese domestic market)
Toyota Harrier (non-US areas)
1997--2000 Toyota Sienna
1998--2003 Toyota Solara (V6)
2000--2005 Toyota Estima (Japanese domestic marketplace)

Toyota rushing developing supplied a bolt-on TRD supercharger kit the MY1997--2000 Camry, MY1998--2000 Sienna and MY1999--2000 Solara. Power result was bumped to 242 hp and 242 lb*ft of torque.

The 1MZ-FE with VVT-i can be used when you look at the Avalon, Highlander, Sienna and Camry. Result try 210 hp (156 kW) at 5800 rpm with 222 lb*ft (328 N*m) of torque at 4400 rpm. Early models associated with the VVT-i 1MZ utilized a dual throttle human anatomy, cast aluminum consumption manifold, and EGR block off plates on the fatigue manifolds. Later on variations used a drive-by-wire/electronic throttle controls.


1998--2003 Lexus RX 300 (US marketplace)
1999--2003 Lexus ES 300
1999--2004 Toyota Avalon
2000--2003 Toyota Highlander/Kluger
2000--2003 Toyota Sienna
2002--2007Toyota Alphard (Japanese domestic marketplace)
2003--2006 Toyota Camry (V6)

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