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Toyota Highlander Service Repair Manual 2001-2007

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Welcome to the comprehensive service and repair manual for the Toyota Highlander, covering model years 2001 through 2007. As a popular mid-size crossover SUV, the Highlander is recognized for its...
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Tipo: Car
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SKU: 104865
Toyota Highlander Service Repair Manual 2001-2007
Welcome to the comprehensive service and repair manual for the Toyota Highlander, covering model years 2001 through 2007. As a popular mid-size crossover SUV, the Highlander is recognized for its reliability, comfort, and practicality, making it an excellent choice for families. Built with renowned engineering quality, this vehicle offers a spacious interior, optional third-row seating, and available All-Wheel Drive, providing versatility for various driving needs. Its unibody construction ensures a car-like ride, distinguishing it from traditional body-on-frame SUVs and contributing to its comfortable and refined driving experience. This manual provides in-depth coverage for all models and engines within the specified production years, including the 1MZ-FE (3.0L V6), 3MZ-FE (3.3L V6), and 2AZ-FE (2.4L I4). It details every aspect of the vehicle, from scheduled maintenance and routine repairs to complex diagnostics and component overhauls. You will find step-by-step procedures, detailed illustrations, and essential technical specifications for engine systems, transmissions, braking, suspension, steering, electrical components, and HVAC. This resource is designed to empower owners, mechanics, and technicians with the knowledge necessary to maintain, troubleshoot, and repair the Toyota Highlander effectively, ensuring its longevity and optimal performance.
🏷️ Basic Information
Identification
Make:
Toyota
Model:
Highlander
Production Years Covered:
2001, 2002, 2003, 2004, 2005, 2006, 2007
Vehicle Class:
Mid-size Crossover SUV
Codes
Chassis Code First Gen:
XU20
Engine Codes:
1MZ-FE (3.0L V6), 3MZ-FE (3.3L V6), 2AZ-FE (2.4L I4)
👋 Introduction
Market Position
Vehicle Segment:
Popular mid-size, three-row crossover SUV, positioned as a family-friendly vehicle
Key Selling Points:
Reliability, comfort, practicality, available AWD, spacious interior
Competitive Analysis
Primary Competitors:
Ford Explorer, Honda Pilot, Nissan Murano, Chevrolet Trailblazer, Mazda CX-9
Competitive Advantage:
Toyota's reputation for reliability and lower long-term ownership costs
Key Features
Unique Features:
Optional third-row seating, unibody construction (for a more car-like ride compared to body-on-frame SUVs)
Target Demographic:
Families, individuals seeking versatility and practicality
📋 Manual Details
Coverage Areas
Manual Type:
Complete Service & Repair Manual
Language:
English
Format:
Digital (PDF, likely)
Breadth Of Coverage:
All models and engines for the specified production years
Depth Of Coverage:
Every detail on the car
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, lubrication, cooling, fuel delivery, ignition, emissions control, engine management (ECU/PCM), forced induction (if applicable)
Transmission Systems:
Automatic transmission (U150E, U250E), transfer case, drive shafts, differentials, AWD system components
Braking Systems:
Front and rear brakes (disc), ABS, EBD, brake system bleeding, parking brake
Suspension Steering:
Front struts, rear shocks, control arms, springs, bushings, power steering system, steering column, alignment specifications
Electrical Systems:
Battery, charging system, starting system, lighting, instrument cluster, interior/exterior electrical components, fuses, relays, wiring diagrams
HVAC Systems:
Air conditioning, heating, ventilation, climate control system diagnostics and repair
Body Interior:
Body panels, doors, windows, seats, interior trim, glass replacement, seals, body hardware
Chassis Frame:
Frame construction, mounting points, corrosion protection
Procedures Included
Maintenance:
Scheduled maintenance (oil changes, filter replacements, fluid checks), tune-ups, belt replacements, spark plug replacement
Diagnostics Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting, component testing procedures
Repair Rebuild:
Engine component repair, transmission overhaul, brake caliper replacement, suspension component replacement, steering rack rebuild
Component Replacement:
Detailed instructions for replacing virtually all mechanical and electrical components
Specifications Data:
Torque specifications, clearances, fluid capacities, diagnostic values, alignment data
Technical Depth
Scope:
Comprehensive (from basic fluid changes to complete engine/transmission rebuilds)
Diagnostic Level:
Advanced diagnostics, including electrical troubleshooting and ECU parameter analysis
Repair Detail:
Step-by-step procedures with detailed illustrations and diagrams
📊 Manual Specifications
File Format
Format Type:
PDF
Searchability:
Likely text-searchable (if digitally generated)
Print Quality
Illustration Clarity:
High-resolution, clear diagrams and illustrations
Text Readability:
Crisp, easily readable text
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine 1:
3.0L DOHC V6 (1MZ-FE)
Engine 1 Horsepower:
220 hp @ 6000 rpm
Engine 1 Torque:
222 lb-ft @ 4400 rpm
Engine 2:
3.3L DOHC V6 (3MZ-FE) - Introduced in 2004
Engine 2 Horsepower:
230 hp @ 5600 rpm (2004-2005), 230 hp @ 5600 rpm (2006-2007)
Engine 2 Torque:
242 lb-ft @ 3600 rpm (2004-2005), 242 lb-ft @ 3600 rpm (2006-2007)
Engine 3:
2.4L DOHC I4 (2AZ-FE) - Introduced in 2004 for specific markets/trims
Engine 3 Horsepower:
160 hp @ 5800 rpm
Engine 3 Torque:
163 lb-ft @ 4000 rpm
Performance
Compression Ratio 1Mzfe:
9.6:1
Compression Ratio 3Mzfe:
10.0:1
Bore Stroke 1Mzfe:
87.5 mm x 83.0 mm
Bore Stroke 3Mzfe:
92.0 mm x 83.0 mm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Sequential Multi-port Fuel Injection (SFI)
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
18.5 gallons (70 liters)
🔧 Transmission
Standard
Transmission Type:
4-speed automatic (U150E)
Optional
Transmission Type Optional:
5-speed automatic (U250E) - Introduced in 2004 for 3.3L V6 models
Features
Drivetrain Options:
Front-Wheel Drive (FWD), All-Wheel Drive (AWD)
AWD System:
Electronically controlled, active torque split AWD system
Transmission Fluid Spec:
Toyota ATF WS (World Standard) or equivalent (check manual for exact specification for specific transmission)
📐 Dimensions
Exterior
Length:
Approx. 189.9 inches (4825 mm)
Width:
Approx. 72.2 inches (1835 mm)
Height:
Approx. 67.1 inches (1705 mm)
Wheelbase:
Approx. 106.9 inches (2715 mm)
Ground Clearance:
Approx. 7.5 inches (190 mm)
Interior
Passenger Capacity:
5 or 7 (with optional third-row seat)
Cargo
Cargo Volume Behind 2Nd Row:
Approx. 39.7 cu ft (1124 liters)
Cargo Volume Behind 3Rd Row:
Approx. 10.1 cu ft (286 liters)
Cargo Volume Max:
Approx. 83.0 cu ft (2350 liters)
Weights
Curb Weight FWD:
Approx. 3700-3800 lbs (1678-1724 kg)
Curb Weight AWD:
Approx. 3900-4000 lbs (1769-1814 kg)
Towing Capacity:
Up to 3500 lbs (1588 kg) with V6 models
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance:
4 out of 5 stars (for most years/configurations)
IIHS Frontal Offset Impact:
Good (for most years/configurations)
IIHS Side Impact:
Good (for most years/configurations)
Active Features
ABS:
Standard Anti-lock Braking System
Ebd:
Standard Electronic Brake-force Distribution
Traction Control:
Standard Traction Control System (TRAC)
Electronic Stability Control:
Standard Vehicle Stability Control (VSC) - Introduced from 2004 model year onwards
Passive Features
Airbags Front:
Standard driver and front passenger airbags
Airbags Side:
Optional front side-impact airbags and side-curtain airbags (availability varies by trim and year)
Seatbelts:
3-point seatbelts with pretensioners and force limiters
Latch Anchors:
Standard LATCH (Lower Anchors and Tethers for CHildren) system
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player, optional premium JBL audio system
Display Screen:
Optional touchscreen navigation system (late models)
Climate Control:
Manual or automatic climate control
Driver Assistance
Cruise Control:
Standard cruise control
Parking Assist:
Optional rear parking assist sensors (late models)
Connectivity
Auxiliary Input:
Optional auxiliary audio input jack
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles (8,000 km) or 6 months, whichever comes first (or 10,000 miles/16,000 km with synthetic oil, consult manual)
Air Filter Replacement:
Every 30,000 miles (48,000 km) or as needed based on driving conditions
Cabin Air Filter:
Every 15,000 miles (24,000 km) or annually
Spark Plug Replacement 1Mzfe:
Approx. 100,000 miles (160,000 km) with iridium-tipped plugs
Timing Belt Replacement:
Not applicable - these engines use a timing chain.
Fluid Specifications
Engine Oil Capacity 30L V6:
Approx. 4.5 quarts (4.3 liters) with filter (1MZ-FE)
Engine Oil Capacity 33L V6:
Approx. 4.5 quarts (4.3 liters) with filter (3MZ-FE)
Engine Oil Type:
SAE 5W-30 (API certified, synthetic recommended for extended intervals)
Coolant Type:
Toyota Super Long Life Coolant (SLLC) or equivalent (Pink)
Power Steering Fluid:
Toyota Genuine Power Steering Fluid or Dexron II/III ATF (consult manual)
Known Issues
Common Problem 1:
Oil leaks (valve cover gaskets, oil pan gaskets)
Common Problem 2:
Exhaust manifold cracks (especially on earlier V6 models)
Common Problem 3:
Mass Airflow Sensor (MAF) issues causing rough idle or stalling
Common Problem 4:
Wheel bearing wear
Common Problem 5:
HVAC blower motor resistor failure
Common Problem 6:
Transmission shifting issues (less common, but possible with high mileage)
📚 Vehicle History
Brand Heritage
Manufacturer:
Toyota Motor Corporation
Brand Reputation:
Renowned for reliability, durability, and quality (Toyota Production System)
Model Evolution
Introduction Year:
2001
First Generation:
XU20 (2001-2007)
Major Updates First Gen:
Facelift and engine upgrade (3.3L V6, 2.4L I4) for the 2004 model year.
Platform:
Shared platform with the Toyota Camry and Lexus RX (RX300/RX330)
Production
Manufacturing Locations:
Primarily manufactured in North America (TMMW - Toyota Motor Manufacturing, West Virginia, USA)
Production Volume:
Significant sales volume, contributing to Toyota's SUV market share
🏆 Awards & Recognition
Recognitions
Award 1:
Kiplinger's Personal Finance: Best New Sport-Utility Vehicle (2001)
Award 2:
MotorWeek: Best Family Hauler (2001)
Award 3:
J.D. Power and Associates: Vehicle Quality Awards (multiple instances for dependability)
Ratings
Reliability Rating:
Consistently rated as excellent for reliability by consumer reports and automotive publications.
Certifications
Certification Body:
N/A (Focus on industry awards and consumer ratings)
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