Toyota CH-R Service Manual: Back Door Support

Components

COMPONENTS

ILLUSTRATION

*1

BACK DOOR DAMPER STAY LOWER BRACKET

*2

BACK DOOR DAMPER STAY UPPER BRACKET

*3

BACK DOOR STAY ASSEMBLY

*4

STOP RING

N*m (kgf*cm, ft.*lbf): Specified torque

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Precoated part

-

-

Installation

INSTALLATION

CAUTION / NOTICE / HINT

HINT:

  • Use the same procedure for the RH side and LH side.
  • The following procedure is for the LH side.

PROCEDURE

1. INSTALL BACK DOOR DAMPER STAY LOWER BRACKET

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

(b) Apply adhesive to the threads of the 2 bolts.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(c) Install the 2 bolts and back door damper stay lower bracket.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

2. INSTALL BACK DOOR DAMPER STAY UPPER BRACKET

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

(b) Apply adhesive to the threads of the 2 bolts.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(c) Install the back door damper stay upper bracket with the 2 bolts.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

3. INSTALL BACK DOOR STAY ASSEMBLY

CAUTION:

  • Do not perform work if the back door is not securely supported.
  • The back door could fall, resulting in injury.

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.
  • 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.
  • Do not apply any horizontal load to the door stay in order to prevent the piston rod from deforming.

(a) When reusing the back door stay assembly:

(1) Install the 2 stop rings to the back door stay assembly.

(b) Install the back door stay assembly.

NOTICE:

  • Install the back door stay assembly while supporting the back door by hand.
  • Check that the back door stay assembly is engaged in the ball joint and that the back door support assembly cannot be pulled out.

Removal

REMOVAL

CAUTION / NOTICE / HINT

HINT:

  • Use the same procedure for the RH side and LH side.
  • The following procedure is for the LH side.

PROCEDURE

1. REMOVE BACK DOOR STAY ASSEMBLY

CAUTION:

  • Do not perform work if the back door is not securely supported.
  • The back door could fall, resulting in injury.

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.
  • 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.
  • Do not apply any horizontal load to the door stay in order to prevent the piston rod from deforming.

(a) Using a screwdriver with its tip wrapped in protective tape, remove the 2 stop rings as shown in the illustration.

*a

Protective Tape

(b) Release the ball joint to remove the back door stay assembly.

NOTICE:

  • Remove the back door stay assembly while supporting the back door by hand.
  • Remove the back door stay assembly while supporting the back door stay assembly by hand.

2. REMOVE BACK DOOR DAMPER STAY UPPER BRACKET

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

3. REMOVE BACK DOOR DAMPER STAY LOWER BRACKET

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

Disposal

DISPOSAL

PROCEDURE

1. DISPOSE OF OF BACK DOOR STAY ASSEMBLY

(a) Fully extend the back door stay assembly.

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

(c) Wearing protective glass, gradually cut the shaded part between "A" and "B" shown the illustration using a metal saw to gradually release the gas.

Specification:

Area

Measurement

A - B

53.5 mm (2.11 in.)

CAUTION:

Always use proper safety equipment and be careful when drilling because shards of metal way fly about.

HINT:

The gas is colorless, odorless and non-poisonous.

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