The 2005 Highlander is a mid-size crossover SUV celebrated for its renowned reliability, comfortable ride, and spacious interior. Designed for families seeking versatility, it offers a smooth 3.0L V6 DOHC engine paired with a 5-speed automatic transmission, available in both Front-Wheel Drive and Electronic On-Demand All-Wheel Drive configurations. Its robust engineering, coupled with a strong safety record and practical features, positions it as a dependable choice in its segment, offering a blend of comfort, capability, and enduring quality. This comprehensive factory service manual provides in-depth information essential for the maintenance, repair, and diagnostics of your 2005 Highlander. Covering a vast array of systems including the engine, transmission, drivetrain, suspension, brakes, steering, electrical system, HVAC, and body, it details routine maintenance procedures, component replacement, engine and transmission overhauls, and advanced troubleshooting. With detailed technical specifications, wiring diagrams, and guidance on special tools, this manual serves as an invaluable resource for owners, technicians, and mechanics aiming to ensure the optimal performance and longevity of their vehicle. 🏷️ Basic Information Identification Make: Toyota Model: Highlander Year: 2005 Generation: First Generation (XU20) Codes Chassis Code: XU20 👋 Introduction Market Position Vehicle Segment: Mid-size Crossover SUV Target Audience: Families seeking a versatile, reliable, and comfortable SUV with the Toyota reputation for quality. Competitive Analysis Key Competitors: Honda CR-V, Ford Escape, Nissan Murano, Subaru Outback, Chevrolet Equinox. Key Features Unique Selling Points: Renowned Toyota reliability, comfortable ride, spacious interior, available all-wheel drive, smooth V6 engine. Manual Value Proposition: Provides comprehensive, accurate, and officially licensed repair information, empowering owners and technicians to perform maintenance and repairs effectively, saving on dealership service costs. 📋 Manual Details Coverage Areas Primary Coverage: North America Page Count Estimated Pages: Approximately 3000+ pages (typical for comprehensive factory service manuals) Manual Type Type: Official Factory Service Manual / Repair Manual Software Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed coverage of 3.0L (1MZ-FE) V6 DOHC engine, including maintenance, diagnostics, overhaul procedures, and component testing. Engine Management: Exhaust Gas Recirculation (EGR), Ignition system, Fuel Injection system, Emissions control systems. Transmission: U151E 5-speed automatic transmission, including overhaul, diagnostics, shift control, torque converter, and fluid service. Drivetrain: Front-Wheel Drive (FWD) and Electronic On-Demand Four-Wheel Drive (4WD) systems, including differential, driveshafts, and CV joints. Suspension: Front MacPherson strut and rear independent multi-link suspension, including alignment specifications, component replacement, and diagnostics. Brakes: Front and rear disc brakes (Vented front, Solid rear), ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), Brake assist, Parking brake system. Steering: Power assisted rack and pinion steering, steering column, and related components. Electrical System: 12V battery, charging system (alternator), starting system, lighting system (headlights, taillights, interior), fuses, relays, and wiring diagrams. Body And Frame: Exterior panels, interior trim, doors, glass, body sealing, collision repair information. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant servicing, blower motor, and climate control operation. Restraint Systems: SRS (Supplemental Restraint System) - Airbags, seatbelt pretensioners, and related sensors. (Cautionary notes for SRS system work are critical). Diagnostics And Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting, diagnostic tools and procedures, on-board diagnostics (OBD-II). Procedures Included Routine Maintenance: Oil change, filter replacement (oil, air, cabin), fluid checks and top-offs, tire rotation, spark plug replacement. Component Replacement: Alternator, starter motor, water pump, thermostat, fuel pump, brake pads/rotors, suspension components, exhaust system. Troubleshooting Fault Finding: Systematic diagnosis of malfunctions using schematics, test procedures, and diagnostic equipment. Engine Rebuilding: Complete engine overhaul procedures, including cylinder head removal/installation, piston and connecting rod service, crankshaft service. Transmission Overhaul: Detailed steps for disassembly, inspection, repair, and reassembly of the automatic transmission. Electrical Diagnostics: Troubleshooting wiring issues, sensor testing, actuator testing, and module diagnostics. Alignment Procedures: Front and rear wheel alignment specifications and adjustment procedures. Climate Control Service: Refrigerant system evacuation and recharge, leak testing, component replacement within the HVAC system. Body Repair: Panel removal and installation, door adjustments, glass replacement, and basic collision repair techniques. Technical Depth Depth Of Coverage: Comprehensive factory-level repair and diagnostic information, suitable for professional technicians and advanced DIY enthusiasts. Diagnostic Tools: Detailed use of Toyota's diagnostic tools (e.g., Techstream) and generic OBD-II scanners for fault code retrieval and data analysis. Torque Specifications: Precise torque values for all critical fasteners throughout the vehicle. Wiring Diagrams: Detailed electrical wiring schematics for all vehicle systems, aiding in troubleshooting electrical faults. Special Tools: Identification and usage of specialized tools required for specific repair procedures. 📊 Manual Specifications File Format PDF Quality: High-resolution, searchable PDF for easy navigation and text extraction. Print Quality: Optimized for printing individual pages or sections as needed. Binding Type Binding: Not Applicable (Digital PDF Download) Paper Type Paper Type: Not Applicable (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Code: 1MZ-FE Engine Type: 3.0L V6 DOHC (Double Overhead Camshaft) 24-valve Performance Horsepower: 220 hp @ 5800 rpm (approximate, depending on specific market tuning) Torque:...