Page 2137 of 2572
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
Page 2138 of 2572
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
Page 2139 of 2572
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.
Page 2140 of 2572
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.
Page 2141 of 2572

'05 HIGHLANDER_U (L/O 0409)
2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)
Publication No. OM48570U
Part No. 01999-48570
Printed in Japan 01- 0411- 00
Quick index
If a service reminder indicator or warning buzzer comes on 135. . . . . . . .
If your vehicle will not start 332. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
If your engine stalls while driving 335. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
If your vehicle overheats 336. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
If you have a flat tire 337. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
If your vehicle needs to be towed 349. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tips for driving during break- in period 291. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to start the engine 318. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General maintenance 367. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Complete index NO TAG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas station information
Fuel type:
2AZ- FE engine: UNLEADED gasoline, Octane Rating 87
(Research Octane Number 91) or higher
3MZ- FE engine: UNLEADED gasoline, Octane Rating 87
(Research Octane Number 91) or higher
For improved vehicle performance, the use of premium unleaded
gasoline with an Octane Rating of 91 (Research Octane Number 96)
or higher is recommended.
See page 291 for detailed information.
Fuel tank capacity:
72.5 L (19.1 gal., 16.0 Imp.gal.)
Engine oil:
API grade SL Energy- Conservingº or ILSAC multigrade engine oil is
recommended.
See page 381 for detailed information.
Tire information: See pages 385 through 393.
Tire inflation pressure: See page 410.
U-8
C
Page 2142 of 2572

BODY DIMENSIONS
Three-dimensional
distanceCenter-to-center
straight-line
distance
Two-dimensional
distanceCenter-to-center
Horizontal distance
in forward / rearward
Vertical distance
in centerVertical distance
in lower surface
Imaginary Standard Line
Under Surface of
The Rocker Panel
Imaginary Standard Line
DI-1
GENERAL INFORMATION
1. BASIC DIMENSIONS
(a) There are two types of dimensions in the diagram.
(1) (Three-dimensional distance)
Straight-line distance between the centers of two
measuring points.
(2) (Two-dimensional distance)
Horizontal distance in forward / rearward between the
centers of two measuring points.
The height from an imaginary standard line.
(b) In cases in which only one dimension is given, left and right
are symmetrical.
(c) The dimensions in the following drawing indicate actual dis-
tance. Therefore, please use the dimensions as a refer-
ence.
(d) The line that connects the places listed below is the imagi-
nary standard line when measuring the height. (The dimen-
sions are printed in the text.)
SYMBOLName
1The place that was lowered A mm from the under surface of
the rocker panel centered on the front jack up point.
2The place that was lowered B mm from the under surface of
the rocker panel centered between 1 and 3.
3The place that was lowered C mm from the under surface of
the rocker panel centered on the rear jack up point.
Page 2143 of 2572
Plate Looseness
Body Looseness
Pointer Looseness
Pointer
Master Gauge
Wrong Correct
Pointer
BODY DIMENSIONSDI-2
2. MEASURING
(a) Basically, all measurements are to be done with a tracking
gauge. For portions where it is not possible to use a track-
ing gauge, a tape measure should be used.
(b) Use only a tracking gauge that has no looseness in the
body, measuring plate, or pointers.
HINT:
1) The height of the left and right pointers must be equal.
2) Always calibrate the tracking gauge before measuring
or after adjusting the pointer height.
3) Take care not to drop the tracking gauge or otherwise
shock it.
4) Confirm that the pointers are securely in the holes.
(c) When using a tape measure, avoid twists and bends in the
tape.
Page 2144 of 2572

F10004
F10001A
F10002A
F10003A
Glass Cover
Seat Cover
WRONG
WRONG
INTRODUCTION
GENERAL REPAIR INSTRUCTIONS
1. WORK PRECAUTIONS
(a) VEHICLE PROTECTION
(1) When welding, protect the painted surfaces, windows,
seats and carpet with heat resistant, fire-proof covers.
(b) SAFETY
(1) Never stand in direct line with the chain when using a
puller on the body or frame, and be sure to attach a
safety cable.
(2) Before performing repair work, check for fuel leaks.
If a leak is found, be sure to close the opening totally.
(3) If it is necessary to use a flame in the area of the fuel
tank, first remove the tank and plug the fuel line.
(c) SAFETY WORK CLOTHES
(1) In addition to the usual mechanic's wear, cap and
safety shoes, the appropriate gloves, head protector,
glasses, ear plugs, face protector, dust-prevention
mask, etc. should be worn as the situation demands.
CodeName
ADust-Prevention Mask
BFace Protector
CEye Protector
DSafety Shoes
EWelder's Glasses
FEar Plugs
GHead Protector
HWelder's Gloves