TOYOTA HIGHLANDER 2001 Service Repair Manual

BODY PANEL REPLACEMENT
F16724
BP-66
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
F16725
F16725A
REMOVALBP-67
REAR FLOOR NO.2 CROSSMEMBER (ASSY)
REPLACEMENT

BODY PANEL REPLACEMENT
F16726
BP-68
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
F16717
PART NAME
[A] Rear Floor Center Crossmember
20 mm (0.79 in.)[B] Rear Floor No.2 Crossmember
F16717A
REMOVAL BP-56
REAR FLOOR PAN (CUT)
REPLACEMENT
With the body lower back panel removed.

BODY PANEL REPLACEMENT
F12093
POINT
1 Cut the new part so that it overlaps the previous cut location by approximately 20 mm (0.79 in.).
2 Attach the weld bolt to center of the bearing surface.
PART NAME
[C] Rear Floor Side Panel Rear Extension
[E] Rear Floor Pan No.2 Extension
[H] Spare Wheel Carrier Bracket[D] Rear Floor Panel Extension
[F] Weld Bolt [G] Rear Floor Heat Insulator No.3 BracketBP-57
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
F16718
POINT
1*1: Plug weld the overlapping portion of the [J].
HINT:
1) Be sure the portion to be welded are align and not loose.
2 Coat the overlapping opening portion from the both sides with body sealer.
PART NAME
[A] Rear Floor Center Crossmember
[I] 3rd Seat Floor Side Panel[B] Rear Floor No.2 Crossmember
[J] New Part BP-58

BODY DIMENSIONS
(Three-Dimensional Distance)
Symbol Name Hole dia. Symbol Name Hole dia.mm (in.)
A, a
B, b
C, c
D, dRadiator upper support installation bolt
Headlight installation screw
Front end of front fender
Headlight installation screwÐ
Ð
Ð
ÐE, e
F, f
G, g
ÐFront fender installation bolt
Front fender installation bolt
Front fender installation bolt
ÐÐ
Ð
Ð
Ð
A-e A-E D-g D-G
or or C-c or or
a-E a-e d-G d-g
1,145 332 1,435 1,590 711
(45.08) (13.07) (56.50) (62.60) (27.99)
Vehicle Dimensions
1,479
(58.23)
709
(27.91)
1,613
(63.50)
365
(14.37)
1,511
(59.49)
1,258
(49.53)
599
(23.58)1,370
(53.94)
1,232
(48.50)1,084
(42.68)848
(33.39)179
(7.05)
1,453
(57.20)
DI-13
REFERENCE VALUE
ENGINE COMPARTMENT

(Two-Dimensional Distance)
Front bumper reinforcement
Front spring support Rear spring support
NUT
NUT
26.2 76.9
76.9
31.1 12.6

57.4 56.812.6

32.3
64.7
0.632.412.5
60.6
38.4 40.533.42.9
11.4

9.6 3.1

3.5
0.3
21.9
mm
BODY DIMENSIONSDI-14
UNDER BODY

2005 HIGHLANDER (EWD592U)
20
F RELAY LOCATIONS
[Engine Compartment]
[Instrument Panel]

2005 HIGHLANDER (EWD592U)
21
F
[Body]
[Seat]