TOYOTA HIGHLANDER 2001 Service Repair Manual

BODY PANEL REPLACEMENT
F16742
BP-2
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
F16768
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.
F16768A
REMOVAL BP-36
REAR DOOR OUTER PANEL (ASSY)
REPLACEMENT

BODY PANEL REPLACEMENT
F16769
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-37
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.

F14883
POINT
1 Remove the [A] and [B] at the same time.
PART NAME
[A] Front Floor Panel Side Plate[B] Fuel Tank Support Bracket
F14883B
REMOVALBODY PANEL REPLACEMENT
BP-59
REAR FLOOR CENTER CROSSMEMBER
(ASSY)
REPLACEMENT

F14884
PART NAME
[A] Front Floor Panel Side Plate
[C] Rear Floor Crossmember No.2 Reinforcement[B] Fuel Tank Support BracketBODY PANEL REPLACEMENT
BP-60
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
F16719
F16719A
REMOVALBP-61
REAR FLOOR PAN TO QUARTER PANEL
EXTENSION (ASSY)
REPLACEMENT
With the rear floor pan removed.

BODY PANEL REPLACEMENT
F16720
BP-62
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
F16721
85 mm (3.35 in.)
F16721A
REMOVALBP-63
REAR FLOOR SIDE REAR MEMBER (CUT-H)
REPLACEMENT
With the body lower back panel removed.

BODY PANEL REPLACEMENT
F16722
BP-64
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
F16723
F16723A
REMOVALBP-65
REAR FLOOR SIDE REAR MEMBER (ASSY)
REPLACEMENT
With the body lower back panel removed.