Back Door Support

1. REMOVE BACK DOOR DAMPER STAY SUB-ASSEMBLY LH

NOTICE:

• Avoid touching the piston rod as much as possible to prevent foreign matter from attaching to it. Be sure to hold the cylinder while servicing the vehicle.
• Do not wear cotton gloves or other similar materials when handling the piston rod. Fibers may attach to the rod and result in gas leaks.
• In order to prevent the piston rod from deforming, do not apply any horizontal load to the door damper stay.

(a) Using a screwdriver, remove the stop ring along the groove. HINT: Tape the screwdriver tip before use. Text in Illustration *1 Protective Tape

(b) Release the ball joint and remove the back door damper stay sub-assembly.

NOTICE:

Remove the back door damper stay sub-assembly while supporting the back door by hand.

2. REMOVE BACK DOOR STAY BOLT

(a) Remove the back door stay bolt. NOTICE: If the hood support is detached from the ball joint, it becomes non-reusable. Therefore, do not detach the hood support from the ball joint unless replacing it.

3. REMOVE BACK DOOR UPPER DAMPER STAY BRACKET LH

(a) Remove the 2 bolts and back door upper damper stay bracket.

1. DISPOSE OF BACK DOOR DAMPER STAY SUB-ASSEMBLY LH

(a) Secure the back door damper stay sub-assembly horizontally in a vise with the piston rod pulled out.

(b) Wear safety glasses. Using a metal saw, slowly cut a groove between A and B shown in the illustration to release the gas. Standard: Area Measurement A - B 100 mm (3.94 in.) B - C 30 mm (1.18 in.) CAUTION: Although the gas inside the back door damper stay sub-assembly is colorless, odorless and harmless, metal debris may scatter. Therefore, cover the back door damper stay sub-assembly with a piece of cloth or other material.

1. INSTALL BACK DOOR UPPER DAMPER STAY BRACKET LH

(a) Install the back door upper damper stay bracket with the 2 bolts. HINT: Tighten the bolts in the order shown in the illustration. Torque: 20 N·m {204 kgf·cm, 15 ft·lbf}

2. INSTALL BACK DOOR STAY BOLT

(a) Clean the threaded portion on the vehicle body with a non-residue solvent.

(b) Apply adhesive to the threads of the bolt.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(c) Install the back door stay bolt. Torque: 18 N·m {184 kgf·cm, 13 ft·lbf}

3. INSTALL BACK DOOR DAMPER STAY SUB-ASSEMBLY LH

NOTICE:

• Avoid touching the piston rod as much as possible to prevent foreign matter from attaching to it. Be sure to hold the cylinder while servicing the vehicle.
• Do not wear cotton gloves or other similar materials when handling the piston rod. Fibers may attach to the rod and result in gas leaks.
• In order to prevent the piston rod from deforming, do not apply any horizontal load to the door damper stay.

(a) Install a new back door damper stay sub-assembly. NOTICE: Install the back door damper stay sub-assembly while supporting the back door by hand. Check that the back door stay assembly is attached to the ball joint and that the back door damper stay sub-assembly cannot be pulled out.