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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Body & Frame >> Exterior/Interior Trim >> Exterior Panels / Trim - Service Information (1 Of 2) >> FRONT BUMPER (except Sport Package) >> Reassembly [12/2019 - ] >> Procedure

Reassembly [12/2019 - ]: Procedure

  1. INSTALL FRONT BUMPER SIDE STAY LH 

    HINT: 

    Perform this procedure only when replacement of the front bumper side stay LH is necessary.

    1. Engage the claw.
      GTY897092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the 2 clips as shown in the illustration.
    3. Install the front bumper side stay LH with the bolt.
      GTY897097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 5.4 N.m (55 kgf/cm, 48 in.lbf) 

  2. INSTALL FRONT BUMPER SIDE STAY RH 

    HINT: 

    Use the same procedure as for the LH side.

  3. INSTALL NO. 2 FRONT BUMPER REINFORCEMENT 

    HINT: 

    Perform this procedure only when replacement of the No. 2 front bumper reinforcement is necessary.

    1. Install the No. 2 front bumper reinforcement with the 4 nuts.

      Torque: 18 N.m (184 kgf/cm, 13 ft.lbf) 

      GTY897094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY 

    HINT: 

    Perform this procedure only when replacement of the front bumper reinforcement sub-assembly is necessary.

    1. Install the front bumper reinforcement sub-assembly with the 8 bolts.

      Torque: 35 N.m (357 kgf/cm, 26 ft.lbf) 

      GTY939151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the 2 clamps.
      GTY897100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FRONT BUMPER LOWER ABSORBER 

    HINT: 

    Perform this procedure only when replacement of the front bumper lower absorber is necessary.

    1. Engage the 2 guides to install the front bumper lower absorber.
      GTY897101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL FRONT BUMPER ENERGY ABSORBER 

    HINT: 

    Perform this procedure only when replacement of the front bumper energy absorber is necessary.

    1. Engage the 2 guides to install the front bumper energy absorber.
      GTY897098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FRONT BUMPER LOWER COVER 
    1. for Type A:
      1. When reusing the front bumper cover but replacing the front bumper lower cover with a new one, remove the spring nut that is attached to the front bumper cover.
        GTY1250351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        HINT: 

        • When replacing the front bumper cover, replace the front bumper lower cover with a new one.
        • Do not reuse the spring nut that was removed from the front bumper cover; discard it.
        • Use the same procedure as for the LH side.
    2. Engage the 14 claws.
      GTY897099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 4 clips.
      GTY1177885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the front bumper lower cover to front bumper cover with the 4 screws.
      GTY1250427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL FRONT VALANCE PANEL SUB-ASSEMBLY (w/ Front Valance Panel) 
    1. Engage the 11 guides.
      GTY908842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the front valance panel sub-assembly with the 11 clips.
      GTY897142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL FRONT BUMPER HOLE COVER LH 
    1. Engage the hook.
      GTY851516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hook
    2. Engage the 2 claws to install the front bumper hole cover LH.
  10. INSTALL FRONT BUMPER HOLE COVER RH 

    HINT: 

    Use the same procedure as for the LH side.

  11. INSTALL FOG LIGHT COVER LH 
    1. Engage the 2 claws.
      GTY897146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the fog light cover LH with the 2 screws.
      GTY897144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL FOG LIGHT COVER RH 

    HINT: 

    Use the same procedure as for the LH side.

  13. INSTALL RADIATOR GRILLE SUB-ASSEMBLY 
    1. Engage the 3 guides and 10 clips.
      GTY897145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the radiator grille sub-assembly with the 2 screws.
      GTY939164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL NO. 1 FRONT BUMPER LOWER RETAINER 
    1. Install the No. 1 front bumper lower retainer with the screw.
      GTY897150Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL RADIATOR GRILLE (OR FRONT PANEL) EMBLEM 
    1. Engage the 2 claws.
      GTY897147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the radiator grille (or front panel) emblem with the 2 screws.
      GTY897148Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL FRONT BUMPER MOULDING 
    1. Engage the 3 guides and 8 clips.
      GTY896858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the front bumper moulding with the 2 screws.
      GTY896859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL RADIATOR GRILLE BRACKET 
    1. Engage the 6 guides.
      GTY939096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the 3 guides and 4 claws.
      GTY896857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 10 screws and 2 clips.
      GTY862098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Screw Clip
    4. Install the radiator grille bracket with the 2 clips.
      GTY896860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL HOOD TO RADIATOR GRILLE SEAL 
    1. Connect the hood to radiator grille seal as shown in the illustration.
      GTY939097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Use the same procedure for the LH side and RH side.

    2. Engage the 16 clips to install the hood to radiator grille seal.
  19. INSTALL FRONT BUMPER EXTENSION MOUNTING BRACKET 
    1. Install the front bumper extension mounting bracket with the 2 screws.
      GTY896864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL ULTRASONIC SENSOR CLIP 

    HINT: 

    When installing the ultrasonic sensor clip, heat the front bumper cover using a heat light.

    Heating Temperature

    Item Temperature
    Front Bumper Cover 20 to 30 °C (68 to 86 °F)
    WARNING:
    • Do not touch the heat light and heated parts, touching the heat light may result in burns.
    • Touching heated parts for a long time may result in burns.
    GTY583249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Heated Part
    *b Heat Light
    NOTE:

    Do not heat the front bumper cover excessively.

    1. Clean the front bumper cover surface.
      1. Using a heat light, heat the front bumper cover surface.
      2. Remove the double-sided tape from the front bumper cover.
      3. Wipe off any tape adhesive residue with cleaner.
    2. Using a brush or felt, apply primer or equivalent to the ultrasonic sensor clip installation area.
      GTY887995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Primer
    3. Install a new ultrasonic sensor clip.
      1. Using a heat light, heat the front bumper cover surface.
      2. Remove the release paper from the ultrasonic sensor clip.

        HINT: 

        After removing the release paper, keep the exposed adhesive free from foreign matter.

      3. Install each ultrasonic sensor clip as shown in the illustration.
        GTY914107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *A w/ Intuitive Parking Assist System - -
        *a Line - -

        HINT: 

        • Install the ultrasonic sensor clip within the line on the front bumper cover.
        • Press the ultrasonic sensor clip firmly to install it.
  21. INSTALL NO. 4 ENGINE ROOM WIRE (w/o Intuitive Parking Assist System) 
    1. Engage the 9 clamps to install the No. 4 engine room wire.
      GTY939093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL NO. 4 ENGINE ROOM WIRE (w/ Intuitive Parking Assist System) 
    1. Engage each clamp to install the No. 4 engine room wire.
      GTY901180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A w/ Panoramic View Monitor System - -
  23. INSTALL FRONT CORNER ULTRASONIC SENSOR RETAINER (w/ Intuitive Parking Assist System) 

    Refer to PROCEDURE - Step 2 [12/2019 - 11/2023] , or refer to PROCEDURE - Step 2 [11/2023 - ]

  24. INSTALL FRONT CENTER ULTRASONIC SENSOR RETAINER (w/ Intuitive Parking Assist System) 

    Refer to PROCEDURE - Step 3 [12/2019 - 11/2023] , or refer to PROCEDURE - Step 3 [11/2023 - ]

  25. INSTALL FRONT CORNER ULTRASONIC SENSOR (w/ Intuitive Parking Assist System) 

    Refer to PROCEDURE - Step 4 [12/2019 - 11/2023] , or refer to PROCEDURE - Step 4 [11/2023 - ]

  26. INSTALL FRONT CENTER ULTRASONIC SENSOR (w/ Intuitive Parking Assist System) 

    Refer to PROCEDURE - Step 5 [12/2019 - 11/2023] , or refer to PROCEDURE - Step 5 [11/2023 - ]

  27. INSTALL FRONT TELEVISION CAMERA ASSEMBLY (w/ Panoramic View Monitor System) 

    Refer to PROCEDURE - Step 1

  28. INSTALL MILLIMETER WAVE RADAR SENSOR ASSEMBLY 

    Refer to PROCEDURE - Step 1 [12/2019 - 09/2020] , or refer to PROCEDURE - Step 1 [09/2020 - ]

  29. INSTALL FOG LIGHT ASSEMBLY LH (w/ Fog Light) 

    Refer to PROCEDURE - Step 1 [12/2019 - 09/2020] , or refer to PROCEDURE - Step 1 [09/2020 - ]

  30. INSTALL FOG LIGHT ASSEMBLY RH (w/ Fog Light) 

    HINT: 

    Use the same procedure as for the LH side.

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