The 2002 Toyota Highlander is a mid-size crossover SUV designed for families and individuals seeking a versatile vehicle that blends SUV capabilities with car-like handling. Built on a car-based platform derived from the Camry, it offers a refined ride and is powered by a 3.0L V6 engine delivering 200 horsepower. Known for its hallmark reliability and quality, the Highlander aimed to provide a comfortable and practical transportation solution, often featuring optional all-wheel drive for enhanced all-weather capability. Its design philosophy prioritized a balance of performance, comfort, and utility, making it a strong contender in its segment. This comprehensive factory service manual provides detailed information for the 2002 Toyota Highlander, covering all major systems including the powertrain, chassis, electrical components, and body. It includes essential maintenance procedures, diagnostic troubleshooting guides with DTC interpretation and wiring diagrams, and step-by-step repair instructions for component removal, installation, and system overhauls. The manual also identifies specialized tools and outlines technical specifications necessary for accurate maintenance and repair. Its purpose is to serve as an authoritative resource for owners, mechanics, and technicians, ensuring the proper upkeep and longevity of the vehicle. 🏷️ 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 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 ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional TRAC (Traction Control) system, especially with AWD Vsc: 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...