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I'm in the same boat: Try reading all pages on these links:

http://townhall-talk.edmunds.com/direct/view/.f15850c/0

http://forums.automobilemag.com/70/6248778/Toyota/2002-toyota-highlander-problems/index.html

this one has photos how to do the repair:

http://www.tundrasolutions.com/forums/highlander/32217-heater-quit-sort-of/

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17y ago

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