TOYOTA HIGHLANDER 2001 Service Repair Manual

BODY PANEL REPLACEMENT
F16701
F16701A
REMOVALBP-5
FRONT CROSSMEMBER SIDE GUSSET
(ASSY)
REPLACEMENT
With the radiator upper support removed.

BODY PANEL REPLACEMENT
F16702
101 mm (3.98 in.) 200 mm (7.87 in.) POINT
1*1: Reference value
PART NAME
[A] Radiator Support Extension[B] Front Bumper Support BP-6
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
F16766
POINT
1 Before removing the outer panel, make the installation position with a tape.
2 Before removing the outer panel, establish its exact position in relation to the window frame using a reference
marker, etc.
3 After grinding off the hemming location, remove the outer panel.
F16766A
REMOVAL BP-34
FRONT DOOR OUTER PANEL (ASSY)
REPLACEMENT

BODY PANEL REPLACEMENT
F16767
POINT
1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection
beam and back side of the new parts.
HINT:
1) Apply sealer evenly about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter to the outer
panel and apply just enough sealer for the reinforcement and side impact protection beam to make con-
tact.
2 Bend the flange hem about 30 with a hammer and dolly, then fasten tightly with a hemming tool.
HINT:
1) Perform hemming in three steps, being careful not to warp the panel.
2) If a hemming tool cannot be used, hem with a hammer and dolly.
BP-35
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
F16749
POINT
1 Remove the [A] at the same time.
PART NAME
[A] Front Fender Apron Wind Guide Gusset
F16749A
REMOVALBP-13
FRONT FENDER FRONT APRON (ASSY)
REPLACEMENT
With the radiator side support removed.

BODY PANEL REPLACEMENT
F16750
6 mm (0.24 in.) 20 mm (0.79 in.) PART NAME
[A] Front Fender Apron Wind Guide Gusset BP-14
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 DIMENSIONS
(Three-Dimensional Distance)
Symbol Name Hole dia. Symbol Name Hole dia.mm (in.)
A, a
B, b
C, cFront frame standard hole
Front frame standard hole
Front frame standard hole13 (0.51)
13 (0.51)
13 (0.51)D, d
E, e
ÐFront frame standard hole
Lower arm installation hole
Ð13 (0.51)
15 (0.59)
Ð
Imaginary
Standard
Line Front
700
(27.56)
920
(36.22)
945
(37.20)
879
(34.61)
616
(24.25)
738
(29.06)
658
(25.91)
520
(20.47)
486
(19.13)
676
(26.61)
1,029
(40.51)
63
(2.48)57
(2.24)72
(2.83)38
(1.50)55
(2.17)55
(2.17)38
(1.50)72
(2.83)57
(2.24)63
(2.48)
DI-11
FRONT FRAME

BODY DIMENSIONS
(Two-Dimensional Distance)
Symbol Name Hole dia. Symbol Name Hole dia.mm (in.)
A, a
B, b
C, cFront frame standard hole
Front frame standard hole
Front frame standard hole13 (0.51)
13 (0.51)
13 (0.51)D, d
E, e
ÐFront frame standard hole
Lower arm installation hole
Ð13 (0.51)
15 (0.59)
Ð
Imaginary
Standard
Line Front
350
(13.78) 635 (25.00)
505 (19.88)
14 (0.55)
104 (4.09)104 (4.09) 14 (0.55) 505 (19.88) 635 (25.00)350
(13.78)
460
(18.11)460
(18.11)
338
(13.31)338
(13.31)
369
(14.53)
243
(9.57)243
(9.57)
369
(14.53)
63
(2.48)57
(2.24)72
(2.83)38
(1.50)55
(2.17)55
(2.17)38
(1.50)72
(2.83)57
(2.24)63
(2.48)
DI-12
FRONT FRAME

BODY PANEL REPLACEMENT
F16703
PART NAME
[A] Front Side Member Extension
265 mm (10.43 in.)
F16703A
REMOVALBP-19
FRONT SIDE MEMBER (CUT-P)
REPLACEMENT
With the front crossmember No.1 reinforcement removed.

BODY PANEL REPLACEMENT
F16704
PART NAME
[A] Front Side Member Extension[B] Body Mounting No.1 Bracket BP-20
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.