2002 Toyota Highlander Service & Repair Manual Software

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🏷️ Basic Information Identification Make: Toyota Model: Highlander Year: 2002 Codes Chassis Code: XU20 👋 Introduction Market Position Segment: Mid-size Crossover SUV (CUV) Target Audience: Families, individuals seeking a versatile...

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Description

🏷️ Basic Information

Identification

Make:

Toyota

Model:

Highlander

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Mid-size Crossover SUV (CUV)

Target Audience:

Families, individuals seeking a versatile vehicle with SUV-like capabilities and car-like handling.

Competitive Analysis

Key Competitors:

Honda CR-V, Ford Escape, Nissan Xterra, Subaru Forester, Chevrolet Tracker

Key Features

Design Philosophy:

Car-based platform (derived from Camry) offering improved ride comfort and handling compared to truck-based SUVs, with optional all-wheel drive.

Powertrain Options:

Focus on the V6 engine for a balance of power and refinement.

📋 Manual Details

Coverage Areas

Primary Coverage:

2002 Toyota Highlander

Secondary Coverage:

Early XU20 generation

Page Count

Estimated Pages:

Over 2000 (typical for comprehensive factory service manual)

Manual Type

Type:

Factory Service Manual (FSM) / Repair Manual Software

Language

Language:

English

Format

Format:

PDF Download (Software)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, transmission, drivetrain, fuel system, exhaust system

Chassis:

Suspension (front and rear), steering, brakes (hydraulic, ABS), wheels, tires

Electrical:

Engine control, body control, lighting, infotainment, power accessories, starting and charging, diagnostics

Body:

Body panels, interior trim, exterior trim, doors, windows, HVAC system, safety systems (SRS)

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, inspections

Diagnostics:

Troubleshooting guides, DTC (Diagnostic Trouble Code) interpretation, wiring diagrams, diagnostic procedures for all major systems

Repair:

Component removal and installation, system repair, sub-assembly repair, rebuild procedures

Special Tools:

Identification and usage of specialized tools required for specific procedures

Technical Depth

Depth:

Comprehensive, from basic fluid checks to complete engine and transmission overhauls, including detailed electrical schematics and diagnostic trees.

📊 Manual Specifications

File Format

Compatibility:

Viewable on PC, Mac, tablets, and smartphones with PDF reader software. Searchable text functionality.

Print Quality

Quality:

High-resolution scans ensuring clear diagrams, illustrations, and text. Printable pages.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

1MZ-FE

Configuration:

3.0L V6, DOHC, 24-valve

Performance

Horsepower:

200 hp @ 5,200 rpm

Torque:

207 lb-ft @ 4,000 rpm

Fuel System

Induction:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline, 87 octane (recommended)

Technical Details

Bore X Stroke:

87.0 mm x 83.0 mm

Compression Ratio:

9.8:1

Timing System:

Dual Overhead Camshafts (DOHC), timing belt

🔧 Transmission

Standard

Type:

4-speed Electronically Controlled Automatic Transmission (ECT)

Optional

Type:

N/A (No manual transmission option offered for this model year)

Features

Drive Modes:

Includes 'ECT PWR' mode for enhanced acceleration.

Fluid Specifications

Fluid Type:

Toyota ATF WS (World Standard) or equivalent DEXRON III/MERCON

Fluid Capacity

Capacity:

Approximately 3.5 Quarts (3.3 Liters) for a fluid change.

📐 Dimensions

Exterior

Length:

184.5 inches

Width:

71.5 inches

Height:

67.1 inches

Wheelbase:

106.5 inches

Interior

Passenger Volume:

Approx. 103.7 cubic feet

Cargo

Cargo Volume Behind 2Nd Row:

Approx. 37.0 cubic feet

Cargo Volume With 2Nd Row Folded:

Approx. 77.3 cubic feet

Weights

Curb Weight:

Approx. 3,770 - 3,925 lbs (depending on drivetrain)

Towing Capacity:

3,500 lbs (when properly equipped)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

5-Star Driver, 4-Star Passenger (2002 Model Year)

NHTSA Side Impact:

4-Star Front, 4-Star Rear (2002 Model Year)

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional TRAC (Traction Control) system, especially with AWD

Optional Vehicle Stability Control (VSC) on some higher trims/later in production year.

Passive Features

Airbags:

Standard front airbags. Optional side-impact airbags for front occupants.

Seatbelts:

Three-point seatbelts with pretensioners for all seating positions.

Child Anchors:

LATCH (Lower Anchors and Tethers for Children) system.

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM/CD player. Optional premium JBL audio system with subwoofer available on higher trims. Cassette player also common.

Climate Control:

Manual or Automatic Climate Control systems, often with dual-zone capability on higher trims.

Driver Assistance

Cruise Control:

Standard electronic cruise control.

Connectivity

Aux Input:

Not standard. Aftermarket solutions often used for audio device connectivity.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles or 6 months, whichever comes first (using conventional oil). Synthetic oil can extend this interval as per manufacturer recommendation in manual.

Engine Air Filter:

Inspect every 15,000 miles, replace as needed (typically every 30,000 miles).

Cabin Air Filter:

Inspect annually, replace as needed (typically every 15,000 - 30,000 miles).

Spark Plugs:

Iridium-tipped spark plugs, typically require replacement around 100,000 miles.

Timing Belt:

Crucial: Replacement every 90,000 miles (or 72 months) is critical to prevent catastrophic engine damage.

Fluid Specifications

Engine Oil:

SAE 5W-30 API Certified (Synthetic recommended for optimal performance and longevity).

Engine Oil Capacity:

6.4 US quarts (6.1 Liters) with filter change.

Coolant:

Toyota Super Long Life Coolant (SLLC) - Pink color. Or equivalent HOAT (Hybrid Organic Acid Technology) coolant.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid:

Toyota Genuine Power Steering Fluid or DEXRON II/III ATF.

Known Issues

Common Complaints:

Minor oil leaks (valve cover gaskets, oil pan gasket), potential for alternator failure, AC system refrigerant leaks, occasional ABS/VSC sensor issues.

Timing Belt Related:

While the 1MZ-FE is robust, failure to adhere to the timing belt replacement schedule is the most critical maintenance point.

📚 Vehicle History

Brand Heritage

Brand History:

Toyota's reputation for reliability, quality, and durability is a cornerstone of the Highlander's appeal.

Model Evolution

Generation:

First Generation (XU20) - Launched in 2001 for the 2001 model year, with the 2002 model being an early iteration.

Platform:

Built on the K platform, shared with the Toyota Camry and Lexus RX.

Production

Assembly Locations:

Primarily assembled in Japan. Later, production shifted to North America (Kentucky, USA).

🏆 Awards & Recognition

Recognitions

Safety Awards:

Often received good ratings in NHTSA crash tests for its era, contributing to Toyota's strong safety reputation.

Ratings

Consumer Reports:

Generally received good ratings for reliability and owner satisfaction, aligning with Toyota's brand image.