TOYOTA HIGHLANDER 2001 Service Repair Manual

BODY PANEL REPLACEMENT
F16705
F16705A
REMOVALBP-21
FRONT SIDE MEMBER (ASSY)
REPLACEMENT
With the front fender apron and front crossmember No.1 reinforcement re-
moved.

BODY PANEL REPLACEMENT
F16706
POINT
1 Make sure each measurement is correct, as this parts affects the front wheel alignment.
PART NAME
[A] Front Side Member Extension BP-22
INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)

Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.

After welding, apply the polyurethane foam to the corresponding parts.

After welding, apply body sealer and under-coating to the corresponding parts.

After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.

BODY PANEL REPLACEMENT
F16759
POINT
1*1: This part of the outer panel is reused, because the rocker panel section is cut off at the rear position behind
the supplied parts cut position of the outer panel.
50 mm (1.97 in.) 100 mm (3.94 in.) 120 mm (4.72 in.)
F16759A
REMOVALBP-27
FRONT BODY PILLAR (CUT)
REPLACEMENT
With the cowl top to apron brace and front body pillar lower gusset removed.

BODY PANEL REPLACEMENT
F16760
POINT
1 Remove the [A] at the same time.
PART NAME
[A] Front Pillar Upper Inner Extension BP-28

BODY PANEL REPLACEMENT
F16761
10 mm (0.39 in.) 380 mm (14.96 in.) POINT
1 Before temporarily installing the new parts, weld the [B], [C] and [D] with standard points.
PART NAME
[B] Rocker Outer Reinforcement[C] Front Body Upper Inner Pillar [D] Outer PanelBP-29
INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)

Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.

After welding, apply the polyurethane foam to the corresponding parts.

After welding, apply body sealer and under-coating to the corresponding parts.

After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.

BODY PANEL REPLACEMENT
F16762
10 mm (0.39 in.) 15 mm (0.59 in.) 50 mm (1.97 in.) POINT
1 Inspect the fitting of the front door, front fender and windshield glass, etc., before welding, since this affects the
appearance of the finish.
PART NAME
[A] Front Pillar Upper Inner Extension BP-30

BODY PANEL REPLACEMENT
F16751
POINT
1 Remove the [A], [B] and [C] at the same time.
PART NAME
[A] Front Apron To Cowl Side Lower Member
[C] Cowl Top To Cowl Inner No.2 Brace (LH), Cowl Top To Cowl Inner No.1 Brace (RH)[B] Cowl Top Side Reinforcement
F16751A
REMOVALBP-15
FRONT APRON TO COWL SIDE UPPER
MEMBER (ASSY)
REPLACEMENT
With the radiator side support removed.

BODY PANEL REPLACEMENT
F16752
POINT
1 Inspect the fitting of the front fender and hood, etc., before welding, since this affects the appearance of the
finish.
PART NAME
[A] Front Apron To Cowl Side Lower Member
[C] Cowl Top To Cowl Inner No.2 Brace (LH), Cowl Top To Cowl Inner No.1 Brace (RH)[B] Cowl Top Side Reinforcement BP-16
INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)

Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.

After welding, apply the polyurethane foam to the corresponding parts.

After welding, apply body sealer and under-coating to the corresponding parts.

After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.

BODY PANEL REPLACEMENT
F16757
F16757A
REMOVALBP-25
FRONT BODY PILLAR LOWER GUSSET
(ASSY)
REPLACEMENT

BODY PANEL REPLACEMENT
F16758
BP-26
INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)

Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.

After welding, apply the polyurethane foam to the corresponding parts.

After welding, apply body sealer and under-coating to the corresponding parts.

After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.